Toyota Corolla 1988-1997 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 through 13

  1. Remove the transaxle from the vehicle.
  2.  



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Fig. Fig. 1: Exploded view of the clutch components

  1. Matchmark the flywheel and the clutch cover with paint or chalk.
  2.  
  3. Loosen each set bolt one at a time until the spring tension is relieve.
  4.  
  5. Remove the set bolts completely and pull off the clutch cover with the clutch disc.
  6.  

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

  1. Unfasten the release fork bearing clips. Withdraw the release bearing assembly with the fork and then separate them.
  2.  
  3. Remove the release fork boot.
  4.  
  5. Using calipers, measure the rivet head depth. Minimum depth is 0.012 inch (0.30mm). If not within the limit, replace the clutch disc.
  6.  
  7. Using a dial indicator and V-blocks, measure the clutch disc runout. Maximum allowable runout is 0.031 inch (0.8mm). If the runout is excessive, replace the clutch disc.
  8.  
  9. Using a dial indicator, measure the flywheel runout. Maximum runout is 0.004 inch (0.10mm). If the runout is excessive, machine or replace the flywheel.
  10.  
  11. Using calipers, measure the diaphragm spring for depth and width and wear. Maximum depth is 0.024 inch (0.60mm) and maximum width is 0.020 inch (5mm). Replace the clutch cover as necessary.
  12.  
  13. Grasp the release bearing and turn it while applying force in the axial direction. Replace the bearing and hub as required.
  14.  

To install the clutch:
  1. Insert proper alignment tool into the clutch disc and set them and the clutch cover in position.
  2.  
  3. Install the clutch disc bolts and tighten them evenly and gradually in a criss-cross pattern in several passes around the cover until they are snug.
  4.  
  5. Once the bolts are snug, tighten them in sequence to 14 ft. lbs. (19 Nm).
  6.  
  7. Using a dial indicator with a roller attachment, measure the diaphragm spring tip alignment. Maximum non-alignment is 0.020 inch (0.05mm). Adjust the alignment as necessary using SST No. 09333-00013 or equivalent.
  8.  
  9. Apply molybdenum disulphide lithium base grease (NLGI No.2) to the following parts:
    1. Release fork and hub contact point.
    2.  
    3. Release fork and push rod contact point.
    4.  
    5. Release fork pivot point.
    6.  
    7. Clutch disc spline.
    8.  
    9. Inside groove of the release bearing hub.
    10.  

  10.  
  11. Install the bearing assembly on the fork and then install them to the transaxle.
  12.  
  13. Install the boot.
  14.  
  15. Install the transaxle to the engine.
  16.  



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Fig. Fig. 2: Place matchmarks on the flywheel and clutch cover



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Fig. Fig. 3: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 4: ... then carefully remove the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 5: Check across the flywheel surface, it should be flat



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Fig. Fig. 6: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 7: ... then remove the flywheel from the crankshaft in order replace it or have it machined



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Fig. Fig. 8: Upon installation, it is usually a good idea to apply a thread-locking compound to the flywheel bolts



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Fig. Fig. 9: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 10: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 11: You may want to use a thread locking compound on the clutch assembly bolts



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Fig. Fig. 12: Tighten the bolts on the clutch cover in this order



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Fig. Fig. 13: Be sure to use a torque wrench to tighten all bolts

ADJUSTMENTS



Pedal Height

See Figure 14

  1. Check that the height of the clutch pedal is correct by measuring from the top of the pedal to the asphalt sheet on the kick panel. The pedal height should be within these specifications:
  2.  



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Fig. Fig. 14: Pedal height is the distance between the pedal and the floor board



1988-93: 5.71-6.10 inch (145-155mm)
 
1993-94: 5.61-6.00 inch (142.5-152.5mm)
 
1995: 5.65-6.06 inch (138.5-148.5mm)
 
1996-97: 5.449-5.843 inch (138.4-148.4mm)
 

  1. Loosen the lock nut and turn the stopper bolt until the pedal height is correct and tighten the lock nut.
  2.  
  3. After the pedal height is adjusted, check the pedal free play and pushrod play.
  4.  

Pedal Free-Play

See Figure 15

Measure the clutch pedal free play and pushrod play by pressing on the clutch pedal with your finger and until resistance is felt. The clutch free play should be between 0.197-0.591 inch (5-15mm). Inadequate free play wears all parts of the clutch releasing mechanisms and may cause slippage. Excessive free play may cause inadequate release and hard shifting of gears.



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Fig. Fig. 15: Push in the pedal until the beginning of clutch resistance is felt

If necessary, adjust the free play and pushrod play as follows:

  1. Loosen the lock nut and turn the master cylinder push rod while depressing the clutch pedal lightly with your finger until the free play and pushrod play is correct.
  2.  
  3. Tighten the lock nut.
  4.  
  5. Check the pedal height.
  6.  

Pushrod Play

Push in on the pedal with a finger softly until the resistance begins to increase somewhat. The push rod play at the pedal top should be: 0.039-0.197 inch (1.0-5.0mm).

 
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