The
Oldcorollas FAQ
An FAQ dealing with KE1x to KE7x Toyota Corollas
Supplement to http://groups.yahoo.com/groups/oldcorollas
KE Corolla clutches are cable-operated diaphragm-type mechanisms. It
doesn't get much more simple than that :) TE Corollas have a hydraulic
clutch, and hence a different clutch pedal and fork, as well as a
master cylinder.
In my experience, pedal boxes are interchangeable between auto and
manual cars of the same series. Auto cars usually also have a hole in
the firewall for the clutch cable, but are missing the firewall-mounted
locating horn for the cable holder.
Several manufacturers sell heavy duty kits for KE corollas. These
usually consist of a heavier pressure plate for increased clamping
force onto the flywheel, and a heavier driven plate, sometimes organic
material with what looks like string impregnated in it, sometimes a
modern metallic compound.
Often when fitting a heavier than stock pressure plate, the cable will
stretch in its' sheath, giving poor pedal travel, even with a brand new
genuine Toyota cable (trust me!). Rob Dixon has remedied this problem
by using another clutch horn rubber, reversed, over the stock circlip
adjustment stop. This gives sufficient length to alloy for proper cable
adjustment, and doesn't look dodgy either.
It's a good idea to use two or three circlips for adjustment, in case
one decides to rattle off while you're driving, never to be found
again. I usually pinch a few whenever I go to the wreckers.
During hydro clutch conversions, people usually use TA22 Celica master
cylinders, and modify a stock pedal or a Celica pedal.
A spare gearbox input shaft makes a great clutch centering tool.
Service Specs (KE cable)
Adjust the distance from pedal pad top surface to floor panel upper
surface by means of the pedal support nut and bolt.
RHD pedal height 164mm
LHD pedal height 169mm
To correct pedal play, pull the outer cable at the firewall until
resistance is felt (until the release bearing has contacted the
diaphragm spring). There should be 5 or 6 grooves AND crests (one
groove, one crest equals two) between the circlip and the cable holder
on the firewall.
You should have 20-35mm of play in the clutch pedal until it starts to
disengage.