OEM 2002 Toyota Corolla Clutch Disc

2002 Toyota Corolla Clutch Disc Parts Q&A

• Q: How to service the clutch disc on 2002 Toyota Corolla?

  A: The procedure starts with engine transaxle removal followed by clutch cover and disc extraction when you properly line up clutch cover and flywheel matchmarks while loosening clamping bolts one turn until spring tension releases before drawing the cover and disc out. During this process do not let the clutch disc fall. The service starts by removing the release bearing and fork as one piece before separating them and continuing with the removal of release fork support along with boot. The clutch disc requires inspection using calipers to measure its rivet head depth which should be at least 0.3 mm (0.012 inch). If the measurement falls short, replace the clutch disc. A dial indicator helps check the clutch disc's runout until it reaches 0.8 mm (0.031 inch) while the flywheel runout should not exceed 0.1 mm (0.004 inch) before performing necessary replacements. Measure the diaphragm spring for wear to verify its maximum depth is 0.5 mm (0.020 inch) and maximum width is 6.0 mm (0.236 inch). Then consider replacing the clutch cover if necessary. The inspection includes manual turning of the release bearing with axial loading for determining its replacement needs. The installation process starts with placing Special Service Tool: 09301-00210 on the flywheel but ensuring the clutch disc points towards the correct direction. Then center the matchmarks between both clutch cover and flywheel before tightening the 6 bolts in the sequence to 19 Nm (195 kgf-cm, 14 ft. lbs.), checking for even distribution and disc centering. Follow these steps to check the diaphragm spring tip alignment using a dial indicator until measurement stays below 0.5 mm (0.020 inch). If this measurement is exceeded, use Special Service Tool: 09333-00013 for adjustment. The boot and release fork support needs to be fastened to the transaxle with a torque of 37 Nm (375 kgf-cm, 27 ft. lbs.) Follow this step by spreading molybdenum disulphide lithium base grease (NLGI NO. 2) to the release fork contact points alongside the bearing as well as the push rod and clutch spline. Use product 08887-01706 (100g) of recommended grease to lubricate the release fork and bearing contact points and push rod contact point and pivot point and clutch spline. Reinstall the transaxle with the assembly of the release bearing and fork installed to the transaxle unit.