Toyota Celica 1994-1998 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7



Click image to see an enlarged view

Fig. Fig. 1: View of the clutch plate, disc and related components

  1. Remove the transaxle from the vehicle.
  2.  
  3. Place matchmarks on the flywheel and clutch cover.
  4.  



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Fig. Fig. 2: Place matchmarks on the cover and flywheel before separating the components

  1. Loosen each set bolt one turn at a time until the spring tension is released.
  2.  
  3. Remove the set bolts, then pull off the clutch cover with the disc.
  4.  

Do not drop the clutch disc.

  1. Remove the throw-out bearing and fork form the transaxle. Separate the two components.
  2.  



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Fig. Fig. 3: Slide the throw-out bearing and fork as one unit from the transaxle

  1. Inspect the components.
  2.  

To install:
  1. Install the clutch disc with a guide tool, then set the clutch cover in position.
  2.  



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Fig. Fig. 4: Insert an guide tool into the disc and set the cover and disc on the flywheel

  1. Align the matchmarks on the cover and flywheel. Tighten the bolts on the cover in the order shown to 14 ft. lbs. (19 Nm).
  2.  



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Fig. Fig. 5: Line up the matchmarks and tighten the clutch cover bolts in this sequence

  1. Temporarily tighten the No. 1 and No. 2 bolts.
  2.  
  3. Check the diaphragm spring alignment with a dial indicator with a roller instrument. Alignment should be 0.020 inch (0.5mm).
    1. If alignment is not as specified, using a diaphragm spring alignment tool, position the components correctly.

      Click image to see an enlarged view

      Fig. Fig. 6: Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment

    2.  

  4.  
  5. Apply molybdenum disulphide lithium based grease (NLGI No. 2) to the release fork and hub contact points, release fork and push rod contact point, release fork pivot point and the clutch disc spline.
  6.  



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Fig. Fig. 7: Apply NLGI No. 2 hub grease on the following contact points

  1. Place the throw-out on the release fork, then install the assembly on the transaxle.
  2.  
  3. Attach the transaxle to the engine and secure the components.
  4.  

ADJUSTMENTS



See Figure 8



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Fig. Fig. 8: Clutch pedal adjustment points

Pedal Height
  1. Measure clutch pedal height from the floor to the top of the pedal pad, along the line of pedal travel. The height should be:

    1994-5.86-6.25 inch (148.8-158.9mm)
     
    1995-98-5.70-6.10 inch (144.9-154.9mm)
     

  2.  
  3. Adjust the pedal height, if necessary, by loosening the locknut and turning the adjusting bolt or rotating clutch switch, and retighten the locknut. Now adjust the pedal free-play.
  4.  

Pedal Free-Play

See Figure 9

Push in the pedal until the beginning of the clutch resistance is felt. Resistance is 0.197-0.59 inch (5-15mm).



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Fig. Fig. 9: Pedal free-play is measured by the distance the pedal travels

Push Rod Free-Play

Gently push on the pedal until the resistance begins to increase a little. The push rod free-play at the pedal top should be 0.039-0.197 inch (1.0-5.0mm)

Loosen the locknut and push the rod until the free play and push rod play are correct. Tighten the lock nut, then after adjusting the play, check the pedal height. connect the air duct and install the finish panel.

Clutch Release Point

See Figure 10

  1. Pull the parking brake lever and install a wheel stopper.
  2.  
  3. Start the engine and idle the engine.
  4.  
  5. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact.
  6.  
  7. Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position. Standard distance is 0.98 inch (25mm) or more.
  8.  



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Fig. Fig. 10: Pedal locations for inspecting the clutch release point

If the distance is not as specified, perform the following inspections:



Check the pedal height
 
Check the push rod play and height
 
Bleed the clutch line
 
Check the cover and disc
 

 
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