Clutch Unit (For 3Zr-Fae) Installation

Insert SST into the clutch disc assembly, and then attach them both to the flywheel sub-assembly.

SST

09301-00210

NOTICE:

Insert the clutch disc assembly in the correct direction.

Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.

Following the order shown in the illustration, tighten the 6 bolts, starting with the bolt located near the knock pin at the top.

SST

09301-00210

Torque:

19 N*m{195 kgf*cm, 14 ft.*lbf}

HINT:

1. Following the order in the illustration, tighten the bolts evenly one at a time.
   
2. Move SST up and down, right and left lightly after checking that the clutch disc assembly is in the center, and tighten the bolts.
   

Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

Maximum non-alignment:

0.5 mm (0.0196 in.)

SST

09333-00013

Temporarily install the clutch release cylinder to bleeder tube to a new clutch release with bearing cylinder assembly.

Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.

Install the clutch release with bearing cylinder assembly with 3 new bolts.

Torque:

23 N*m{229 kgf*cm, 17 ft.*lbf}

NOTICE:

1. The clutch release with bearing cylinder and installation bolts cannot be reused and must be replaced with new ones.
   
2. Clean and degrease all installation surfaces and make sure the clutch release with bearing cylinder fits securely with the transaxle during installation. The first bolt should be tightened by hand while holding the clutch release with bearing cylinder.
   
3. Make sure that none of the clutch spline grease adheres to the clutch release with bearing cylinder.
   
4. The clutch release with bearing cylinder cannot be disassembled.
   

Install the clutch tube boot to the manual transaxle assembly.

Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

Temporarily install the clutch release bleeder sub-assembly with the 2 bolts.

Using a union nut wrench, install the clutch release cylinder to bleeder tube to the clutch release with bearing cylinder assembly.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

Apply clutch spline grease to the input shaft spline.

Grease:

Toyota Genuine Clutch Spline Grease or equivalent

Separate the clutch release cylinder to bleeder tube from the clutch release bleeder sub-assembly.

Remove the 2 bolts and clutch release bleeder sub-assembly.

Using SST, apply a pressure of 100 kPa (1.0 kgf/cm², 15 psi) to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

SST

09992-00242

Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

Install the clutch release bleeder sub-assembly with the 2 bolts.

Torque:

17 N*m{170 kgf*cm, 12 ft.*lbf}

Using a union nut wrench, install the clutch release cylinder to bleeder tube.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

Install the clutch orifice assembly with the 2 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Using a union nut wrench, install the clutch release cylinder to accumulator tube.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

Temporarily tighten the orifice to flexible hose tube onto the clutch orifice assembly.

Install the orifice to flexible hose tube with the bolt.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Using a union nut wrench, install the orifice to flexible hose tube.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

for EB61:
Install the manual transaxle assembly (RAV4_ACA30 RM000001B3U02LX.html).

for EB61F:
Install the manual transaxle assembly (RAV4_ACA30 RM000001B3U02WX.html).