Toyota Celica, Corolla, ECHO & MR2 1999-05

Driven Disc & Pressure Plate

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Removal & Installation





Click image to see an enlarged view

Fig. 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.  



Click image to see an enlarged view

Fig. 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.  



Click image to see an enlarged view

Fig. 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.  



Click image to see an enlarged view

Fig. 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.  



Click image to see an enlarged view

Fig. 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. 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.  



Click image to see an enlarged view

Fig. 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.  



Click image to see an enlarged view

Fig. Clutch component assembly-Camry shown, others similar

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Remove the transaxle assembly from the vehicle
     
    Clutch pressure plate retaining bolts
     
    Clutch cover
     
    Clutch disc
     
    Retaining clip and bearing from the transaxle
     
    Release fork and boot assembly
     

  4.  

To install:

  1. Install or connect the following:

    Clutch disc onto the flywheel
     
    Clutch cover, aligning the matchmarks
     
    Clutch cover retaining bolts. Bolts, tightened in a crisscross pattern: 14 ft. lbs. (19 Nm).
     
    Boot, release fork, hub and bearing assemblies
     
    Transaxle
     
    Negative battery cable
     

  2.  


    Click image to see an enlarged view

    Fig. Tighten the pressure plate bolts according to the sequence shown-Camry



NOTE
Do not allow grease or oil to get on any part of the disc, pressure plate, or flywheel surfaces.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding
     
    Transaxle assembly
     

  4.  
  5. Make matchmarks on the clutch cover (pressure plate) and flywheel so that the pressure plate can be returned to its original position during installation.
  6.  
  7. Remove or disconnect the following:

    Release fork bearing clips
     
    Release bearing hub, complete with the release bearing
     
    Release fork and support
     

  8.  


CAUTION
Slowly unfasten the bolts which attach the pressure plate. Loosen each bolt 1 turn at a time until the spring tension is released. If the bolts are released improperly the clutch assembly could fly apart, causing possible injury.



Pressure plate from the clutch cover/spring assembly
 

  1. Inspect the disc, pressure plate and flywheel for damage and wear using a caliper to measure depth and width and a dial indicator to measure runout.
    1. The minimum clutch disc rivet head depth is 0.012 in. (0.3mm).
    2.  
    3. The maximum clutch disc runout is 0.031 in. (0.8mm).
    4.  
    5. The maximum pressure plate spring depth is 0.024 in. (0.6mm).
    6.  
    7. The maximum pressure plate spring width is 0.197 in. (5.0mm).
    8.  
    9. The maximum flywheel runout is 0.004 in. (0.1mm).
    10.  

  2.  
  3. Replace or machine parts as necessary.
  4.  

To install:

  1. When reassembling, apply a thin coating of multipurpose grease to the release bearing hub and release fork contact points. Also, pack the groove inside the clutch hub with multipurpose grease and lubricate the pivot points of the release fork.
  2.  
  3. Install or connect the following:

    Clutch disc and pressure plate. The bolts should be tightened in 2 or 3 steps, gradually and evenly. Final bolt torque is 14 ft. lbs. (19 Nm).
     
    Release bearing, fork and boot
     
    Transaxle assembly
     
    Negative battery cable
     

  4.  



Click image to see an enlarged view

Fig. Clutch component assembly-Camry shown, others similar

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Remove the transaxle assembly from the vehicle
     
    Clutch pressure plate retaining bolts
     
    Clutch cover
     
    Clutch disc
     
    Retaining clip and bearing from the transaxle
     
    Release fork and boot assembly
     

  4.  

To install:

  1. Install or connect the following:

    Clutch disc onto the flywheel
     
    Clutch cover, aligning the matchmarks
     
    Clutch cover retaining bolts. Bolts, tightened in a crisscross pattern: 14 ft. lbs. (19 Nm).
     
    Boot, release fork, hub and bearing assemblies
     
    Transaxle
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Tighten the pressure plate bolts according to the sequence shown-Camry



    Click image to see an enlarged view

    Fig. Be sure to tighten the pressure plate bolts in the correct order-Supra

     

  2.  


NOTE
Do not allow grease or oil to get on any part of the disc, pressure plate, or flywheel surfaces.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding
     
    Transaxle assembly
     

  4.  
  5. Make matchmarks on the clutch cover (pressure plate) and flywheel so that the pressure plate can be returned to its original position during installation.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Slowly unfasten the bolts which attach the pressure plate. Loosen each bolt 1 turn at a time until the spring tension is released. If the bolts are released improperly the clutch assembly could fly apart, causing possible injury.



    Release fork bearing clips
     
    Release bearing hub, complete with the release bearing
     
    Release fork and support
     



    Pressure plate from the clutch cover/spring assembly
     

  8.  
  9. Inspect the disc, pressure plate and flywheel for damage and wear using a caliper to measure depth and width and a dial indicator to measure runout.
    1. The minimum clutch disc rivet head depth is 0.012 in. (0.3mm).
    2.  
    3. The maximum clutch disc runout is 0.031 in. (0.8mm).
    4.  
    5. The maximum pressure plate spring depth is 0.024 in. (0.6mm).
    6.  
    7. The maximum pressure plate spring width is 0.197 in. (5.0mm).
    8.  
    9. The maximum flywheel runout is 0.004 in. (0.1mm).
    10.  

  10.  
  11. Replace or machine parts as necessary.
  12.  

To install:

  1. When reassembling, apply a thin coating of multipurpose grease to the release bearing hub and release fork contact points. Also, pack the groove inside the clutch hub with multipurpose grease and lubricate the pivot points of the release fork.
  2.  
  3. Install or connect the following:

    Clutch disc and pressure plate. The bolts should be tightened in 2 or 3 steps, gradually and evenly. Final bolt torque is 14 ft. lbs. (19 Nm).
     
    Release bearing, fork and boot
     
    Transaxle assembly
     
    Negative battery cable
     

  4.  


NOTE
Do not allow grease or oil to get on any part of the disc, pressure plate, or flywheel surfaces.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding
     
    Transaxle assembly
     

  4.  
  5. Make matchmarks on the clutch cover (pressure plate) and flywheel so that the pressure plate can be returned to its original position during installation.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Slowly unfasten the bolts which attach the pressure plate. Loosen each bolt 1 turn at a time until the spring tension is released. If the bolts are released improperly the clutch assembly could fly apart, causing possible injury.



    Release fork bearing clips
     
    Release bearing hub, complete with the release bearing
     
    Release fork and support
     



    Pressure plate from the clutch cover/spring assembly
     

  8.  
  9. Inspect the disc, pressure plate and flywheel for damage and wear using a caliper to measure depth and width and a dial indicator to measure runout.
    1. The minimum clutch disc rivet head depth is 0.012 in. (0.3mm).
    2.  
    3. The maximum clutch disc runout is 0.031 in. (0.8mm).
    4.  
    5. The maximum pressure plate spring depth is 0.024 in. (0.6mm).
    6.  
    7. The maximum pressure plate spring width is 0.197 in. (5.0mm).
    8.  
    9. The maximum flywheel runout is 0.004 in. (0.1mm).
    10.  

  10.  
  11. Replace or machine parts as necessary.
  12.  

To install:

  1. When reassembling, apply a thin coating of multipurpose grease to the release bearing hub and release fork contact points. Also, pack the groove inside the clutch hub with multipurpose grease and lubricate the pivot points of the release fork.
  2.  
  3. Install or connect the following:

    Clutch disc and pressure plate. The bolts should be tightened in 2 or 3 steps, gradually and evenly. Final bolt torque is 14 ft. lbs. (19 Nm).
     
    Release bearing, fork and boot
     
    Transaxle assembly
     
    Negative battery cable
     

  4.  



Click image to see an enlarged view

Fig. Clutch component assembly-Camry shown, others similar

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Remove the transaxle assembly from the vehicle
     
    Clutch pressure plate retaining bolts
     
    Clutch cover
     
    Clutch disc
     
    Retaining clip and bearing from the transaxle
     
    Release fork and boot assembly
     

  4.  

To install:

  1. Install or connect the following:

    Clutch disc onto the flywheel
     
    Clutch cover, aligning the matchmarks
     
    Clutch cover retaining bolts. Bolts, tightened in a crisscross pattern: 14 ft. lbs. (19 Nm).
     
    Boot, release fork, hub and bearing assemblies
     
    Transaxle
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Tighten the pressure plate bolts according to the sequence shown



    Click image to see an enlarged view

    Fig. Be sure to tighten the pressure plate bolts in the correct order

     

  2.  

 
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