Clutch not working

Tiny
KELLY143
  • MEMBER
  • 2002 TOYOTA COROLLA
  • 4 CYL
  • MANUAL
  • 276,924 MILES
The clutch feels fine when I push on it but you can tell it's not working. The speed gets up to 20 mph but real slow. I didn't hear any loud noises grinding or anything like that. Please help!
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Monday, March 16th, 2020 AT 1:25 PM

3 Replies

Tiny
JACOBANDNICKOLAS
  • EXPERT
Hi,

When you accelerate, does the engine rev but the vehicle not accelerate?

Let me know.
Joe
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Monday, March 16th, 2020 AT 1:31 PM
Tiny
KELLY143
  • MEMBER
That's exactly what it does. And when it's running I'll put my emergency brake on put in fifth gear rev the motor and let go of the clutch in it just stays running stays idling.
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Monday, March 16th, 2020 AT 7:51 PM
Tiny
JACOBANDNICKOLAS
  • EXPERT
It needs a new clutch. It's slipping. The putting it in 5th and letting out the clutch test was a good one. I thought I was the only one that did that to test. LOL

Here are directions for checking and replacing everything. In this case, I would suggest replacing the clutch disc, pressure plate, release bearing, and having the flywheel resurfaced. Here are the directions. The attached pictures correlate with the directions.

_________________________________

2002 Toyota Corolla CE Sedan L4-1.8L (1ZZ-FE)
Procedures
Vehicle Transmission and Drivetrain Clutch Clutch Disc Service and Repair Procedures
PROCEDURES

pic 1

REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE

pic 2

2. REMOVE CLUTCH COVER AND DISC
a. Align the matchmark on the clutch cover with the one on the flywheel.
B. Loosen each set bolt one turn at a time until spring tension is released.
C. Remove the set bolts, and pull off the clutch cover with the clutch disc.

NOTICE: Do not drop the clutch disc.

Pic 3
3. REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE
Remove the release bearing with the fork together and then separate them.
4. REMOVE RELEASE FORK SUPPORT AND BOOT

INSPECTION

pic 4

1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 inch)
If necessary, replace the clutch disc.

Inspect Clutch Disc Runout

pic 5

2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 inch)
If necessary, replace the clutch disc runout.

Pic 6

3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 inch)
If necessary, replace the flywheel.
Torque: 49 Nm (500 kgf-cm, 36 ft. Lbs.)

pic 7

4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 inch)
B (Width): 6.0 mm (0.236 inch)
If necessary, replace the clutch cover.

Pic 8

5. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direction.

HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.

If necessary, replace the release bearing.

INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL

pic 9

a. Insert SST in the clutch disc, then insert them in the flywheel.
SST 09301-00210

HINT: Take care not to insert clutch disc in the wrong direction.

Pic 10

b. Align the matchmarks on the clutch cover and flywheel.
C. Following the procedures shown in the illustration, tighten the 6 bolts in the order starting the bolt locating near the knock pin on the top.
Torque: 19 Nm (195 kgf-cm, 14 ft. Lbs.)

HINT:
Following the order in the illustration, tighten the bolts at a time evenly.
Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.

Pic 11

2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 inch)
If alignment is greater than maximum, using SST, adjust the diaphragm spring tip alignment.
SST 09333-00013
3. INSTALL BOOT AND RELEASE FORK SUPPORT TO TRANSAXLE
Torque: 37 Nm (375 kgf-cm, 27 ft. Lbs.)

pic 12

4. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO. 2)
a. Apply molybdenum disulphide lithium base grease to the release fork and release bearing contact point, release fork and push rod contact point and release fork and pivot point.
B. Apply molybdenum disulphide lithium base grease to the clutch spline.

HINT: Recommended grease part number 08887-01706 (100g).

5. INSTALL RELEASE BEARING AND FORK TO TRANSAXLE
Install the bearing to the release fork, and then install them to the transaxle.
6. INSTALL TRANSAXLE TO ENGINE

________________________________________

You will need to remove the transaxle to replace the clutch. Here are the directions for removal and replacement. The remaining pics correlate with the directions.

_______________________________________

2002 Toyota Corolla CE Sedan L4-1.8L (1ZZ-FE)
Removal and Installation
Vehicle Transmission and Drivetrain Manual Transmission/Transaxle Service and Repair Procedures Removal and Installation
REMOVAL AND INSTALLATION

pic 13

REMOVAL
1. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE

pic 14

2. DISCONNECT CLUTCH RELEASE CYLINDER AND LINE
a. Remove the 4 set bolts of the clutch line bracket.
B. Remove the 2 bolts and disconnect the clutch release cylinder and line.
3. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS

pic 15

4. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
5. DISCONNECT CONTROL CABLE
a. Remove the 2 clips and washers.
B. Remove the 2 clips from the cables.
C. Disconnect the 2 control cables from the transaxle.

Pic 16

6. REMOVE STARTER SET BOLT
Remove the set bolt of the starter from the transaxle upper side.
7. REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS

pic 17

8. INSTALL ENGINE SUPPORT FIXTURE

pic 18

9. REMOVE ENGINE LEFT MOUNTING STAY
Remove the 2 bolts and engine left mounting stay.
10. REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT

pic 19

11. REMOVE ENGINE LEFT MOUNTING BRACKET
Lower the transaxle side and remove the bolt and bracket.
12. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.

13. REMOVE FRONT WHEEL
14. REMOVE LH AND RH ENGINE UNDER COVERS
15. DRAIN TRANSAXLE OIL
16. REMOVE LH AND RH DRIVE SHAFTS

pic 20

17. REMOVE HEAT INSULATOR
Remove the 2 bolts, nut and heat insulator.
18. REMOVE BRACE
Remove the 2 nuts and brace.
19. REMOVE FRONT SUB-FRAME AND LOWER SUSPENSION ARM

pic 21

a. Support the suspension crossmember with a jack.
B. Remove the 2 set bolts of the stabilizer bar bracket.

Pic 22

c. Remove the 14 bolts and 3 nuts.
D. Remove the front sub-frame and lower suspension arm.

Pic 23

20. REMOVE STARTER
a. Disconnect the starter connector.
B. Remove the nut and disconnect the starter wire.
C. Remove the set bolt of the starter from the lower side.
D. Remove the starter.
21. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.

Pic 24

22. REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING BOLTS
23. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the engine.

INSTALLATION
1. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.

2. INSTALL TRANSAXLE TO ENGINE
a. Using a transmission jack, lift up the transaxle.
B. Align the input shaft with the clutch disc and install the transaxle to the engine.
C. Temporarily tighten the 4 transaxle lower side mounting bolts.
3. LOWER VEHICLE

pic 25

4. INSTALL ENGINE LEFT MOUNTING BRACKET
Install the bracket with the bolt.
Torque: 52 Nm (530 kgf-cm, 38 ft. Lbs.)

pic 26

5. INSTALL ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT
Torque:
Bolt A: 52 Nm (530 kgf-cm, 38 ft. Lbs.)
Nut B: 87 Nm (890 kgf-cm, 64 ft. Lbs.)
6. INSTALL ENGINE LEFT MOUNTING STAY
Install the stay with the 2 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft. Lbs.)
7. REMOVE ENGINE SUPPORT FIXTURE
8. RISE VEHICLE

pic 27

9. TIGHTEN TRANSAXLE LOWER SIDE MOUNTING BOLT
a. Tighten the 4 transaxle mounting bolts.
Torque:
Bolt A: 23 Nm (230 kgf-cm, 17 ft. Lbs.)
Bolt B: 47 Nm (480 kgf-cm, 35 ft. Lbs.)
b. Remove the transmission jack.

Pic 28

10. INSTALL STARTER
a. Install the starter.
B. Temporarily tighten the set bolt of the starter from the lower side.
C. Connect the starter connector.
D. Install the starter wire with the nut.
11. INSTALL FRONT SUB-FRAME AND LOWER SUSPENSION ARM
a. Install the front sub-frame and lower suspension arm.

Pic 30

b. Install 2 new bolts, the 12 bolts and 3 nuts.
Torque:
Bolt A: 175 Nm (1,790 kgf-cm, 129 ft. Lbs.)
Bolt B: 147 Nm (1,500 kgf-cm, 109 ft. Lbs.)
Bolt C: 225 Nm (2,305 kgf-cm, 167 ft. Lbs.)
Bolt D: 64 Nm (650 kgf-cm, 47 ft. Lbs.)
Bolt E: 60 Nm (620 kgf-cm, 45 ft. Lbs.)
Nut F: 57 Nm (580 kgf-cm, 42 ft. Lbs.)

pic 31

c. Install the 2 set bolts of the stabilizer bar bracket.
Torque: 147 Nm (1,500 kgf-cm, 109 ft. Lbs.)
12. INSTALL BRACE
Install the brace with the 2 nuts.
Torque: 69 Nm (700 kgf-cm, 51 ft. Lbs.)

pic 32

13. INSTALL HEAT INSULATOR
Install the heat insulator, 2 bolts and nut.
Torque: 17 Nm (170 kgf-cm, 12 ft. Lbs.)
14. INSTALL LH AND RH DRIVE SHAFTS
15. LOWER VEHICLE

pic 33

16. INSTALL 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS
Torque: 64 Nm (650 kgf-cm, 47 ft. Lbs.)
17. INSTALL STARTER SET BOLT
Install the set bolt of the starter from the upper side.
Torque: 37 Nm (378 kgf-cm, 28 ft. Lbs.)
18. CONNECT CONTROL CABLE
a. Connect the 2 control cables to the transaxle.
B. Install the 2 clips to the cables.
C. Install the 2 clips and washers.
19. CONNECT GROUND CABLE
Install the set bolt of the ground cable to the transaxle.
20. CONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS

pic 34

21. CONNECT CLUTCH RELEASE CYLINDER AND LINE
a. Install the clutch release cylinder with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. Lbs.)
b. Install the 4 set bolts of the clutch line bracket.
Torque: 12 Nm (120 kgf-cm, 9 ft. Lbs.)
22. INSTALL BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
23. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.

24. TIGHTEN STARTER SET BOLT
Tighten the set bolt of the starter from the lower side.
Torque: 37 Nm (378 kgf-cm, 28 ft. Lbs.)

25. FILL TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. Qts)
Torque: 37 Nm (400 kgf-cm, 29 ft. Lbs.)
26. INSTALL LH AND RH ENGINE UNDER COVERS
27. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. Lbs.)
28. INSPECT FRONT WHEEL ALIGNMENT
29. DO ROAD TEST
Check for abnormal noises and smooth shifting.

________________________________________

Let me know if this helps or if you have other questions.

Take care,
joe
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Monday, March 16th, 2020 AT 8:23 PM

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