Toyota Corolla 2004 Repair Manual - CLUTCH PEDAL SUB–ASSY

42–2

–CLUTCH CLUTCH PEDAL SUB–ASSY (MTM)

CLUTCH PEDAL SUB–ASSY (MTM)

ADJUSTMENT

1. INSPECT AND ADJUST CLUTCH PEDAL SUB–ASSY

(a) Turn over the floor carpet.

4203L–01

Push Rod Play and
Free Play Adjust Point

Pedal Free Play

Pedal Height
Adjust Point

Push Rod
Play

Pedal Height

(b) Check that the pedal height is correct.

Pedal height from asphalt sheet:

135.8 – 145.8 mm (5.346 – 5.740 in.)

(c) Adjust the pedal height.

(1) Loosen the lock nut and turn the stopper bolt until

the height is correct. Tighten the lock nut.

Torque: 24.5 N⋅m (245 kgf⋅cm, 18 ft⋅lbf)

(d) Check that the pedal free play and push rod play are cor-

rect.
(1) Depress the pedal until the clutch resistance begin

to be felt.

Pedal free play: 5.0 – 15.0 mm (0.197 – 0591 in.)

(2) Gently depress the pedal until the resistance begins

to increase a little.

Push rod play at pedal top:

1.0 – 5.0 mm (0.039 – 0.197 in.)

D26341

(e) Adjust the pedal free play and push rod play.

(1) Loosen the lock nut and turn the push rod until the

free play and push rod play are correct.
(2) Tighten the lock nut.
(3) After adjusting the pedal free play, check the pedal

height.
(4) Connect the air duct and install the lower finish pan-

el.

CL0102

2004 COROLLA (RM1037U)

1499Author: Date:

Full Stroke
End Position

25 mm (0.98 in.) or more

Release Point

CL0512

42–3

–CLUTCH CLUTCH PEDAL SUB–ASSY (MTM)

(f) Check the clutch release point.

(1) Pull the parking brake lever and install wheel stop-

per.
(2) Start the engine and idle the engine.
(3) Without depressing the clutch pedal, slowly shift the

shift lever into reverse position until the gears con-

tact.
(4) Gradually depress the clutch pedal and measure

the stroke distance from the point that the gear

noise stops (release point) up to the full stroke end

position.

Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)

If the distance is not as specified, perform the following opera­tions.

 Check pedal height.
 Check push rod play and pedal free play.
 Bleed the clutch line.
 Check the clutch cover assy and disc assy.

2004 COROLLA (RM1037U)

1500Author: Date: