See Figures 1, 2 and 3
The clutch driven disc may contain asbestos which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from any clutch area! When cleaning clutch surfaces, use commercially available brake cleaning fluids.
Measure the pedal height from the asphalt sheet, except Tercel EZ models, on which the pedal height is measured from the dash panel. Pedal height should be as follows:
- Wagons and 1984-1986 sedans-7.13-7.44 in. (181-189mm)
- 1987-1990 Sedans (except Tercel EZ)-6.14-6.54 in. (156-166mm)
- Tercel EZ models-6.38-6.77 in. (162-172 mm)
- 1991-1994 4-speed Sedans-5.69-6.08 in. (144.5-154.5mm)
- 1991-1994 5-speed Sedans-5.51-5.91 in. (140-150 mm)
- If the pedal height is not as indicated, loosen the lock-nut, then turn the adjusting bolt until the height is correct. On 1987-1990 sedans with cruise control, pedal height is adjusted by turning the clutch switch (loosen the lock-nut and unplug the switch connector first). When pedal height is correct, tighten the lock-nut.
Push rod free-play adjustment is not applicable to wagons and 1984-1986 sedans.
- Check the push rod play. Push in on the pedal softly with your finger until the resistance begins to increase a little. Play at the pedal top should be 0.039-0.197 in. (1-5mm).
- Check the pedal free-play. Push in on the pedal until the beginning of clutch resistance is felt. Pedal free-play should be between 0.08-0.98 in. (2-25mm) on wagons and 1984-1986 sedans, or 0.20-0.59 in. (5-15mm) on 1987-1994 sedans.
- If necessary, adjust the pedal and/or push rod free-play. If free-play is not within specifications on wagons and 1984-1986 sedans, check the release sector and pawl position. If there are less than six notches remaining, replace the clutch disc. On 1987-1994 sedans, loosen the lock-nut and turn the push rod until play is correct, then tighten the lock-nut. Recheck the pedal height.