OEM 2002 Toyota Echo Clutch Disc

2002 Toyota Echo Clutch Disc Parts Q&A

• Q: How to remove and install the clutch disc and related components on 2002 Toyota Echo?

  A: The procedure to remove the clutch disc starts with detaching the transaxle from the engine followed by selecting the matchmarks on the clutch cover and flywheel before slowly rotating the set bolts until spring tension dissipates then sliding off the clutch cover accompanied by the clutch disc while maintaining clutch disc position to avoid dropping it. Begin by taking the release bearing and fork as one piece before disconnecting them and finally removing the release fork support and boot. The clutch disc requires replacement if the vernier caliper measurement reveals rivet head depth below 0.3 mm (0.012 inch). Use a dial indicator to check the clutch disc runout and it must be lower than 0.8 mm (0.031 inch). Additionally measure the flywheel runout using the same tool which should not exceed 0.1 mm (0.004 inch), or obtain a new flywheel if necessary. The diaphragm spring requires inspection for deterioration based on two parameters: maximum depth allowance of 0.5 mm (0.020 inch) and width limit of 6.0 mm (0.236 inch). If either limit is exceeded it is necessary to replace the clutch cover. A hand-operated checking of the release bearing combined with applied axial force can reveal a need for replacement. To install the clutch system use Special Service Tool: 09301-00210 by placing it on the clutch disc before positioning it onto the flywheel in the correct direction then align the matchmarks between clutch cover and flywheel and tighten the 6 bolts in sequence to 19 Nm (195 kgf-cm, 14 ft. lbs.) torque with uniform tension to confirm disc centering. The alignment of diaphragm spring tips must be checked with a dial indicator to ensure 0.5 mm (0.020 inch) maximum distance between points. If any misalignment exists Special Service Tool: 09333-00013 is needed to adjust the position. The process includes applying torque of 37 Nm (375 kgf-cm, 27 ft. lbs.) to secure the boot and release fork support at the transaxle. At this point use Part No. 08887-01806 release hub grease to coat contact points between the fork and hub and Part No. 08887-01706 clutch spline grease must be applied to the input shaft spline. Install the transaxle to the engine after installing its release bearing along with the fork and completing all necessary steps.