OEM 2003 Toyota Corolla Clutch Disc

2003 Toyota Corolla Clutch Disc Parts Q&A

• Q: How to overhaul the clutch disc on 2003 Toyota Corolla?

  A: The overhaul procedure for clutch disc begins with manual transaxle assembly disassembly and then the removal of clutch release fork sub-assembly containing clutch release fork and bearing. The clutch release bearing assembly needs to be broken free from the fork to remove the release fork support from the transaxle assembly. The clutch cover assembly can be detached by centering the matchmarks from the flywheel sub-assembly. Loosen one set of bolts at a time to relieve spring tension until you can remove the six bolts and pull away the clutch cover assembly without letting the clutch disc assembly fall. You should remove the clutch disc assembly while maintaining a clear surface on its lining and pressure plate and flywheel to prevent contamination by oil or foreign materials. Vernier calipers must be used to measure the rivet head depth in the clutch disc assembly and diagnose an excessive reading beyond 0.3 mm (0.012 inch). In such a case, the assembly requires immediate replacement. After proper direction insertion of the clutch disc assembly into the transaxle assembly check its runout using a dial indicator to confirm less than 0.8 mm (0.031 inch) deviation. Replace if runout exceeds the limit. Measure the diaphragm spring wear of the clutch cover assembly with vernier calipers to ensure both depth remains below 0.5 mm (0.020 inch) and width remains less than 6.0 mm (0.236 inch). Change the assembly when necessary. Test the flywheel sub-assembly runout by using a dial indicator to verify it is below 0.1 mm (0.004 inch) because replacement is needed if this value is exceeded. Turn the clutch release bearing assembly manually under axial pressure then change the component if needed. Special Service Tool 09301-00210 should be used to install the clutch disc assembly following correct orientation. Position the matchmarks from both the clutch cover assembly and flywheel sub-assembly before tightening the six bolts to 19.1 Nm (195 kgf-cm, 14 ft. lbs.) at specified torque sequence maintaining uniform clamp load and verifying disc position. Check diaphragm spring tip alignment of the clutch cover assembly with a dial indicator. This alignment should not exceed 0.5 mm (0.020 inch) maximum non-alignment but if needed adjust it using Special Service Tool: 09333-00013. To install the release fork support join the transaxle assembly at 36.8 Nm (375 kgf-cm, 27 ft. lbs.) beforeInstalling the release bearing hub clip and clutch release fork sub-assembly with an application of release hub grease (Part No. 08887-01806) to essential contact areas. The installation requires clutch spline grease (Part No. 08887-01706) on the input shaft spline before putting the bearing into the release fork which leads to the transaxle assembly resulting in proper release fork movement. The manual transaxle assembly and clutch release fork boot need installation as the final steps.