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Wife's RAV4, burnt clutch, DIY #5004508
02/08/19 03:48 AM
02/08/19 03:48 AM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

Joined: Apr 2015
Posts: 485
Reunion Island
Hi,

I maybe underestimated a disaster that was waiting to happen.

When we bought the used car, I noticed the clutch was slipping sometimes, but mainly after engaging each gear.

Later I figured out that hydraulics were the problem, and cleaning slave cylinder (all greasy inside) and flushing fluid solved 80% of clutch behaving issues.

But on occasions, like giving full throttle at sub-midrange RPMs, it slipped anyway until catching up at a higher speed. I then figured that even if clutch pack was replaced somewhere long before the purchase, that hydraulics was likely the root problem and that it continued to wear the actual clutch pack

Fast forward today, it slips at every hill, and I think it won't last more than a work day. I will check hydraulics in a minute to insure it's not sticking.

Any clue of special things when replacing a clutch pack and dual mass flywheel on this MY2001 TOYOTA 1AZ-FE RAV4 ?

Last edited by Superflan; 02/08/19 03:50 AM.

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004531
02/08/19 05:37 AM
02/08/19 05:37 AM
Joined: Aug 2009
Posts: 2,297
PA
Gasbuggy Offline
Gasbuggy  Offline

Joined: Aug 2009
Posts: 2,297
PA
I can't tell you any specific things you will need. But I can say that when I was 20 I replaced a clutch into a FWD toyota with a friend of mine who just like myself, had no clue what he was doing. We got it done and it worked.


Cadillac CTS-V 6.2L 10w30PP
Volvo P1800 5w30 Euro L
LR Series III 10w40 VWB
76' 300D Edge 0w40
02 Yukon 10w30 PP
10 Charger Pursuit 5.7L
95 Accord - 386k. Mobil 2 RIP
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004614
02/08/19 08:24 AM
02/08/19 08:24 AM
Joined: Nov 2011
Posts: 1,499
Lyndhurst NJ
Audios Offline
Audios  Offline

Joined: Nov 2011
Posts: 1,499
Lyndhurst NJ
Youre going to need alot alot alot of time and even more patience. Book time is 18.9 hours for 4wd!!!! This could be a killer for the car depending on how much you want to sink into the car, but we could be in the 3000 range at a shop. Insane!


2002 VW Golf TDI-Mobil 1 5/40 TDT
2007 Mercedes GL320 CDI- M1 0/30 ESP
2005 BMW M3 BMW Twin Power 10/60
2003 BMW M5-Fuchs 5/40
1998 BMW M3/4/5 Fuchs 5/40
Re: Wife's RAV4, burnt clutch, DIY [Re: Audios] #5004625
02/08/19 08:39 AM
02/08/19 08:39 AM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

Joined: Apr 2015
Posts: 485
Reunion Island
18h! Are you sure it's for the same car? Seems overkill


‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004640
02/08/19 09:00 AM
02/08/19 09:00 AM
Joined: Feb 2003
Posts: 8,199
Jupiter, Florida
Cujet Offline
Cujet  Offline

Joined: Feb 2003
Posts: 8,199
Jupiter, Florida
18 hours for a shop means more than that for someone working on jack stands. Yikes.

Cars are such a pain sometimes. As an older guy, I simply don't have the time or energy to be dealing with transmission removals in my driveway. I truly feel for you.

I'd rather be out on my KTM, misbehaving.......


People who count on their fingers should maintain a discreet silence.
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004641
02/08/19 09:02 AM
02/08/19 09:02 AM
Joined: Apr 2008
Posts: 13,247
Central NY
Miller88 Offline
Miller88  Offline

Joined: Apr 2008
Posts: 13,247
Central NY
On vehicles with transverse engines, you have to do a significant amount of extra work.

Front suspension has to come apart to be able to get the axle shafts out. Linkages have to be disconnected (and they are never in good locations). If you're lucky, the transmission can come out the top - otherwise you're dropping a subframe/kmenber/engine cradle/whatever-it-is to get the transmission out. Intake tubes, battery box ... all sorts of junk in the way with transverse engines.


18 Forester 2.5I 6M
00 Jeep XJ
01 F-350 4x4 5M
Re: Wife's RAV4, burnt clutch, DIY [Re: Miller88] #5004644
02/08/19 09:06 AM
02/08/19 09:06 AM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

Joined: Apr 2015
Posts: 485
Reunion Island
Originally Posted by Miller88
On vehicles with transverse engines, you have to do a significant amount of extra work.

Front suspension has to come apart to be able to get the axle shafts out. Linkages have to be disconnected (and they are never in good locations). If you're lucky, the transmission can come out the top - otherwise you're dropping a subframe/kmenber/engine cradle/whatever-it-is to get the transmission out. Intake tubes, battery box ... all sorts of junk in the way with transverse engines.


I'll document it so we can see what we have to see smile it's gonna be interesting


‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004647
02/08/19 09:09 AM
02/08/19 09:09 AM
Joined: Nov 2008
Posts: 13,393
NH
supton Online content
supton  Online Content

Joined: Nov 2008
Posts: 13,393
NH
Being AWD I could see it being a long job.

IIRC it was about an hour to drop the trans in my Jetta. But my mechanic had done it a bunch of times, knew what he was doing. But no extra driveshaft etc in the way.

Cars suck. Sometimes I think about buying new and flipping every 150-200k (6-10 years, give or take). Not the cheapest solution but perhaps least work involved.


2011 Toyota Camry, base, 2.5L/6MT, 181k, hers
2010 Toyota Tundra DC, 4.6L/6AT, 148k, ours
1999 Toyota Camry LE, 2.2L/4AT, 205k, his
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004652
02/08/19 09:21 AM
02/08/19 09:21 AM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

Joined: Apr 2015
Posts: 485
Reunion Island
Duplicate post

Last edited by Superflan; 02/08/19 09:21 AM. Reason: Duplicate post

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: supton] #5004656
02/08/19 09:23 AM
02/08/19 09:23 AM
Joined: Apr 2008
Posts: 13,247
Central NY
Miller88 Offline
Miller88  Offline

Joined: Apr 2008
Posts: 13,247
Central NY
Originally Posted by supton
Being AWD I could see it being a long job.

IIRC it was about an hour to drop the trans in my Jetta. But my mechanic had done it a bunch of times, knew what he was doing. But no extra driveshaft etc in the way.

Cars suck. Sometimes I think about buying new and flipping every 150-200k (6-10 years, give or take). Not the cheapest solution but perhaps least work involved.



I said I was done with new or even newer vehicles. I figured with a small fleet of older vehicles, I could make it work.

Until all three broke at once


18 Forester 2.5I 6M
00 Jeep XJ
01 F-350 4x4 5M
Re: Wife's RAV4, burnt clutch, DIY [Re: Miller88] #5004677
02/08/19 10:00 AM
02/08/19 10:00 AM
Joined: Aug 2015
Posts: 3,128
NC
BigD1 Offline
BigD1  Offline

Joined: Aug 2015
Posts: 3,128
NC
Originally Posted by Miller88
On vehicles with transverse engines, you have to do a significant amount of extra work.

Front suspension has to come apart to be able to get the axle shafts out. Linkages have to be disconnected (and they are never in good locations). If you're lucky, the transmission can come out the top - otherwise you're dropping a subframe/kmenber/engine cradle/whatever-it-is to get the transmission out. Intake tubes, battery box ... all sorts of junk in the way with transverse engines.


Yes they are a royal PITA.

If the trans comes out the bottom, they will probably need an engine support bar.

https://www.harborfreight.com/1000-lb-capacity-engine-support-bar-96524.html


1992 Toyota Pickup--Castrol GTX 10W-40--ACDelco PF53
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004678
02/08/19 10:04 AM
02/08/19 10:04 AM
Joined: Jan 2011
Posts: 3,569
PV Az @ 5000'
AZjeff Online content
AZjeff  Online Content

Joined: Jan 2011
Posts: 3,569
PV Az @ 5000'
Originally Posted by Superflan
Hi,

I maybe underestimated a disaster that was waiting to happen.


We've probably all done that with used cars with varying degrees of work and expense involved to correct the oversight. In another thread someone mentioned a free car that he had $2300 in and wasn't done yet. Ouch.

Grateful I don't have to deal with vehicles in their end of life miles. Hope it all doesn't have to come out the bottom. Good luck.


86 Samurai 1.3 leftovers
14 RAV4 2.5 5W-20 PP
16 Silverado 1500 4.3, DI, AFM 5W-30 PP

The most important thing to do in your life is to not interfere with someone else's life. - Frank Zappa

Re: Wife's RAV4, burnt clutch, DIY [Re: Miller88] #5004682
02/08/19 10:09 AM
02/08/19 10:09 AM
Joined: Nov 2008
Posts: 13,393
NH
supton Online content
supton  Online Content

Joined: Nov 2008
Posts: 13,393
NH
Originally Posted by Miller88
Originally Posted by supton
Being AWD I could see it being a long job.

IIRC it was about an hour to drop the trans in my Jetta. But my mechanic had done it a bunch of times, knew what he was doing. But no extra driveshaft etc in the way.

Cars suck. Sometimes I think about buying new and flipping every 150-200k (6-10 years, give or take). Not the cheapest solution but perhaps least work involved.



I said I was done with new or even newer vehicles. I figured with a small fleet of older vehicles, I could make it work.

Until all three broke at once

LOL Sorry, I can see that happening. MTBF all deciding to hit at once.


2011 Toyota Camry, base, 2.5L/6MT, 181k, hers
2010 Toyota Tundra DC, 4.6L/6AT, 148k, ours
1999 Toyota Camry LE, 2.2L/4AT, 205k, his
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004701
02/08/19 10:29 AM
02/08/19 10:29 AM
Joined: Dec 2006
Posts: 8,452
Canuck living in California
KrisZ Online content
KrisZ  Online Content

Joined: Dec 2006
Posts: 8,452
Canuck living in California
That clutch is toast. A slipping clutch is almost never the fault of hydraulics, unless there is a leak on the clutch, as they are used to disengage the clutch, then the clutch springs engage it and ensure it stays engaged.

I would look for a single mass flywheel conversion kit. It will be less expensive than a dual mass flywheel and should last for the life of this vehicle no problems.

Last edited by KrisZ; 02/08/19 10:31 AM.

2015 Grand Caravan 3.6L - 31k miles.
2006 Mazda 3 2.0L - 171k miles
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004766
02/08/19 11:45 AM
02/08/19 11:45 AM
Joined: Nov 2011
Posts: 1,499
Lyndhurst NJ
Audios Offline
Audios  Offline

Joined: Nov 2011
Posts: 1,499
Lyndhurst NJ
2WD drops it down to 6.7 hours, so heres hoping that its only a front wheel drive?


2002 VW Golf TDI-Mobil 1 5/40 TDT
2007 Mercedes GL320 CDI- M1 0/30 ESP
2005 BMW M3 BMW Twin Power 10/60
2003 BMW M5-Fuchs 5/40
1998 BMW M3/4/5 Fuchs 5/40
Re: Wife's RAV4, burnt clutch, DIY [Re: KrisZ] #5004772
02/08/19 11:48 AM
02/08/19 11:48 AM
Joined: May 2012
Posts: 6,327
Fort Lauderdale, FL
DoubleWasp Online content
DoubleWasp  Online Content

Joined: May 2012
Posts: 6,327
Fort Lauderdale, FL
Agree. Nothing good comes of dual mass flywheels. If it's the type with the springs, I bet some are broken.


07 Lincoln Navigator M1 0w-40/FU
68 Charger R/T / Supercharged 440 VR1/DBL7349
07 Ram 3500 4x4 / Cummins 6.7 /DBL7349
17 Maserati GranTurismo Cabrio
Re: Wife's RAV4, burnt clutch, DIY [Re: Audios] #5004851
02/08/19 01:07 PM
02/08/19 01:07 PM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

Joined: Apr 2015
Posts: 485
Reunion Island
Originally Posted by KrisZ
That clutch is toast. A slipping clutch is almost never the fault of hydraulics, unless there is a leak on the clutch, as they are used to disengage the clutch, then the clutch springs engage it and ensure it stays engaged.

I would look for a single mass flywheel conversion kit. It will be less expensive than a dual mass flywheel and should last for the life of this vehicle no problems.


I have receipt of clutch repair at 80000km or so, it's 144000km and toast. 60000km is rather short for a set. The hydraulics were sticking when pressed, I opened and cleaned 2 times because OEM 17 years DOT3 fill was forming gunk in master and slave cylinder. I guess this wore out the clutch prematurely. I could see the fork still moving when pressing pedal and going out of car before cleaning inside

Seems I'm wrong and it's not a DMF (I'll see it live tomorrow)

Originally Posted by Audios
2WD drops it down to 6.7 hours, so heres hoping that its only a front wheel drive?


It's a 4WD

Last edited by Superflan; 02/08/19 01:09 PM.

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Miller88] #5004883
02/08/19 01:50 PM
02/08/19 01:50 PM
Joined: Oct 2004
Posts: 8,859
Cincinnati, OH, USA
bullwinkle Online confused
bullwinkle  Online Confused

Joined: Oct 2004
Posts: 8,859
Cincinnati, OH, USA
Originally Posted by Miller88
Originally Posted by supton
Being AWD I could see it being a long job.

IIRC it was about an hour to drop the trans in my Jetta. But my mechanic had done it a bunch of times, knew what he was doing. But no extra driveshaft etc in the way.

Cars suck. Sometimes I think about buying new and flipping every 150-200k (6-10 years, give or take). Not the cheapest solution but perhaps least work involved.



I said I was done with new or even newer vehicles. I figured with a small fleet of older vehicles, I could make it work.

Until all three broke at once
That was recently my situation-GMC developed a pretty big fuel leak (hose under the intake, of course), and the xB’s exhaust decided to fall off. Good thing it was 65F & mostly sunny last Saturday! Had to get them fixed before the XJ or F-450 got any ideas...


06 Ram 3500 CTD 4X4(FG Venturi), 93 GMC C3500 6.2, 89 F-450 7.3, 98 XJ 4.0(XG8A), 05 xB(XG3600), 18 Transit 3.7, 03 Merc Grand Marquis 4.6 2V(XG2)
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004894
02/08/19 01:59 PM
02/08/19 01:59 PM
Joined: Dec 2006
Posts: 8,452
Canuck living in California
KrisZ Online content
KrisZ  Online Content

Joined: Dec 2006
Posts: 8,452
Canuck living in California
Originally Posted by Superflan
Originally Posted by KrisZ
That clutch is toast. A slipping clutch is almost never the fault of hydraulics, unless there is a leak on the clutch, as they are used to disengage the clutch, then the clutch springs engage it and ensure it stays engaged.

I would look for a single mass flywheel conversion kit. It will be less expensive than a dual mass flywheel and should last for the life of this vehicle no problems.


I have receipt of clutch repair at 80000km or so, it's 144000km and toast. 60000km is rather short for a set. The hydraulics were sticking when pressed, I opened and cleaned 2 times because OEM 17 years DOT3 fill was forming gunk in master and slave cylinder. I guess this wore out the clutch prematurely. I could see the fork still moving when pressing pedal and going out of car before cleaning inside

Seems I'm wrong and it's not a DMF (I'll see it live tomorrow)


Wow! You learn something new everyday. I never encountered or heard of something like this before. The fluid must've been really gunky to hold off the clutch plate pressure.
Thanks for sharing this.👍


2015 Grand Caravan 3.6L - 31k miles.
2006 Mazda 3 2.0L - 171k miles
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004908
02/08/19 02:13 PM
02/08/19 02:13 PM
Joined: Sep 2015
Posts: 1,750
USA
mk378 Offline
mk378  Offline

Joined: Sep 2015
Posts: 1,750
USA
Sounds like contaminated fluid, in that case the only cure is to replace both cylinders and flush the line well.

Re: Wife's RAV4, burnt clutch, DIY [Re: mk378] #5004935
02/08/19 02:48 PM
02/08/19 02:48 PM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

Joined: Apr 2015
Posts: 485
Reunion Island
Originally Posted by KrisZ

Wow! You learn something new everyday. I never encountered or heard of something like this before. The fluid must've been really gunky to hold off the clutch plate pressure.
Thanks for sharing this.👍

Yeah me neither. The gunk looked like blue « marine » grease

Originally Posted by mk378
Sounds like contaminated fluid, in that case the only cure is to replace both cylinders and flush the line well.

I’ll monitor things carefully but now it’s working good


‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004942
02/08/19 02:53 PM
02/08/19 02:53 PM
Joined: Aug 2010
Posts: 1,516
pa
benjy Offline
benjy  Offline

Joined: Aug 2010
Posts: 1,516
pa
todays clutches being hydraulic generally feed of brake fluid reservoir, at least my 11 nissan frontier does. changing + flushing all fluid is generally every 5 years. can't say anything but good luck + as noted single mass fly + aftermarket can be a lot cheaper, look for you tubes + buy a service manual for specific torques. i would join + look at a Rav IV specific forum as well, good luck!!

Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005000
02/08/19 03:52 PM
02/08/19 03:52 PM
Joined: Nov 2008
Posts: 3,556
Oshawa, Ontario Canada
JC1 Online content
JC1  Online Content

Joined: Nov 2008
Posts: 3,556
Oshawa, Ontario Canada
The OP is in Reunion Island, I doubt there's a HF location close by.

I would try the job myself. Probably need two weekends to get it all done...

Here is a link which may help you. Not sure if any special tools are needed to access everything.

https://pmmonline.co.uk/technical/how-fit-clutch-toyota-rav4/


2015 Grand Caravan SXT Plus 5w-20 Valvoline SynPower/Fram Ultra Filter
1997 Honda Civic CX 5w-30 PPPP/Fram Ultra Filter
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005002
02/08/19 03:56 PM
02/08/19 03:56 PM
Joined: Feb 2014
Posts: 2,861
Canada
Lolvoguy Offline
Lolvoguy  Offline

Joined: Feb 2014
Posts: 2,861
Canada
Hope it's just a hydraulic issue.
I had something similar with my BMW several years ago. The slave was fed off the master cyl (shared res.) and once the brake fluid went low enough, it caused issues with the slave.

Another vote for FWD/RWD


06 Lexus IS350- Wife
88 BMW 325is- Mistress
Say "no" to Turbo!
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005170
02/08/19 07:03 PM
02/08/19 07:03 PM
Joined: Jul 2003
Posts: 5,129
New Zealand
Silk Online content
Silk  Online Content

Joined: Jul 2003
Posts: 5,129
New Zealand
I doubt the hydraulics would wear out the clutch, the release bearing and fingers maybe, but not the clutch plate.

I haven't done the later models, but the first RAV4's were a really pain. you can't pull the gearbox back because it hits the transfer box, you can't remove the transfer because it hits the block. In the shop it's easier to drop the powertrain on the floor and jiggle it all apart. A young guy at work did one in the car last year, it looked nasty because he had the engine hanging at an angle to get the box down. Not something I'd do at home that's for sure.


1987 BMW R65 - Aegis SAE30
2005 Nissan Expert - 5W-40 Castrol Magnatec diesel.
1996 Volvo T5 - Penrite HPR15 - 15W-60. Ryco syntec filter.
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005303
02/08/19 10:01 PM
02/08/19 10:01 PM
Joined: Feb 2003
Posts: 8,199
Jupiter, Florida
Cujet Offline
Cujet  Offline

Joined: Feb 2003
Posts: 8,199
Jupiter, Florida
I’d make extremely sure the pressure plate has free play at the fingers. As a clutch disk wears the free play decreases. Replacement parts may have different dimensions and take up any slack faster.


People who count on their fingers should maintain a discreet silence.
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005374
02/09/19 12:25 AM
02/09/19 12:25 AM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

Joined: Apr 2015
Posts: 485
Reunion Island
New parts

20190209_091747.jpg20190209_092422.jpg

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005624
02/09/19 10:52 AM
02/09/19 10:52 AM
Joined: Nov 2011
Posts: 1,499
Lyndhurst NJ
Audios Offline
Audios  Offline

Joined: Nov 2011
Posts: 1,499
Lyndhurst NJ
Wheres Extra EU?


2002 VW Golf TDI-Mobil 1 5/40 TDT
2007 Mercedes GL320 CDI- M1 0/30 ESP
2005 BMW M3 BMW Twin Power 10/60
2003 BMW M5-Fuchs 5/40
1998 BMW M3/4/5 Fuchs 5/40
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005659
02/09/19 11:24 AM
02/09/19 11:24 AM
Joined: Sep 2015
Posts: 1,750
USA
mk378 Offline
mk378  Offline

Joined: Sep 2015
Posts: 1,750
USA
I read that to mean "somewhere not in the EU." The telephone number would lead to Verona, Italy though.

Last edited by mk378; 02/09/19 11:32 AM.
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005767
02/09/19 01:47 PM
02/09/19 01:47 PM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

Joined: Apr 2015
Posts: 485
Reunion Island
So, the [censored] clutch kit is out. Rivets were licking pressure plate.

Jack up the car, remove wheels, detach control arms, detach wheel pivots, remove x member, remove front driveshafts, remove half airbox, detach clutch slave cylinder, lines, remove starter motor, jack up engine, remove gearbox, done.

It took 3 hours for me and a brother's friend who did it on his RAV4 weeks ago.

Now I need to shave the flywheel that is in bad shape before putting it all back together

Next on Monday with pics

20190209_135647.jpg
Last edited by Superflan; 02/09/19 01:49 PM.

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005777
02/09/19 01:56 PM
02/09/19 01:56 PM
Joined: Jun 2003
Posts: 34,237
ME
eljefino Offline
eljefino  Offline

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Posts: 34,237
ME
well done!

Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005783
02/09/19 02:03 PM
02/09/19 02:03 PM
Joined: Sep 2015
Posts: 1,750
USA
mk378 Offline
mk378  Offline

Joined: Sep 2015
Posts: 1,750
USA

I guess you get used to working like this, being in the Southern Hemisphere.

Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005803
02/09/19 02:25 PM
02/09/19 02:25 PM
Joined: Dec 2006
Posts: 8,452
Canuck living in California
KrisZ Online content
KrisZ  Online Content

Joined: Dec 2006
Posts: 8,452
Canuck living in California
Nice job!

Hiwever, before spending money on resurfacing the flyweel, I would make sure you have enough thickness to play with. It just may be too far gone if the rivets were digging in.


Last edited by KrisZ; 02/09/19 02:26 PM.

2015 Grand Caravan 3.6L - 31k miles.
2006 Mazda 3 2.0L - 171k miles
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005809
02/09/19 02:29 PM
02/09/19 02:29 PM
Joined: May 2005
Posts: 2,311
Toronto, Canada
George7941 Offline
George7941  Offline

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Posts: 2,311
Toronto, Canada
The fingers look very long. All the diaphragm spring clutches I have seen have shorter fingers and part of the diaphragm can been seen, unlike this one where the pressure plate cover hides the diaphragm.


2006 GMC Sierra 4.3l, NV3500,G80 , Mobil 1 5W30, Dexcool.
1987 BMW R80 - sold
2015 Honda CBR300R

Staying out of the right lane a lot.
Re: Wife's RAV4, burnt clutch, DIY [Re: KrisZ] #5005862
02/09/19 03:15 PM
02/09/19 03:15 PM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

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Reunion Island
Originally Posted by mk378
I guess you get used to working like this, being in the Southern Hemisphere.

It was a joke waiting to happen

Originally Posted by KrisZ
However, before spending money on resurfacing the flyweel, I would make sure you have enough thickness to play with. It jus may be too far if the rivets were digging in.
The rivets (those in the friction disc) didnt touch on the flywheel side, only on the pressure plate side, resulting in asymmetrical wear between both sides of the friction disc. I’ll take pics of worn parts tomorrow with a full phone battery smile

Last edited by Superflan; 02/09/19 03:17 PM.

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005994
02/09/19 06:16 PM
02/09/19 06:16 PM
Joined: Nov 2008
Posts: 13,393
NH
supton Online content
supton  Online Content

Joined: Nov 2008
Posts: 13,393
NH
Dumb question: any easier to lift the engine instead? I see you've got it out and done with already, but if I was facing this job, I'd be wondering about that option.

Edit: good job! Sounds like it was quite the task.

Last edited by supton; 02/09/19 06:17 PM.

2011 Toyota Camry, base, 2.5L/6MT, 181k, hers
2010 Toyota Tundra DC, 4.6L/6AT, 148k, ours
1999 Toyota Camry LE, 2.2L/4AT, 205k, his
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5006793
02/10/19 01:22 PM
02/10/19 01:22 PM
Joined: Mar 2010
Posts: 872
Minneapolis
antonmnster Offline
antonmnster  Offline

Joined: Mar 2010
Posts: 872
Minneapolis
Nice work!

Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5008351
02/11/19 09:05 PM
02/11/19 09:05 PM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

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Posts: 485
Reunion Island
Attached you'll find the best I can do for now with the flywheel.

Didn't machine the ring where the dowels come because after balancing there was still a 0.05mm warp. I left that part zlone

20190211_114941-2.jpg
0.10 shaved

20190211_143703.jpg
0.30 final

20190211_143653.jpg
Final close-up

20190211_143643.jpg
Cracks final


‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5008359
02/11/19 09:11 PM
02/11/19 09:11 PM
Joined: Dec 2006
Posts: 8,452
Canuck living in California
KrisZ Online content
KrisZ  Online Content

Joined: Dec 2006
Posts: 8,452
Canuck living in California
The flywheel was definitely heat stressed. Cracks are a dead giveaway, but the different shade spots show the localized overheating quite well. It will probably hold up, but I would take it easy.


2015 Grand Caravan 3.6L - 31k miles.
2006 Mazda 3 2.0L - 171k miles
Re: Wife's RAV4, burnt clutch, DIY [Re: KrisZ] #5008426
02/11/19 10:51 PM
02/11/19 10:51 PM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

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Reunion Island
Originally Posted by KrisZ
The flywheel was definitely heat stressed. Cracks are a dead giveaway, but the different shade spots show the localized overheating quite well. It will probably hold up, but I would take it easy.

Yeah I will not drag race it.

Today I have to put CV shafts back, suspension, replace a tie rod and it should be rolling


‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5008436
02/11/19 11:08 PM
02/11/19 11:08 PM
Joined: Dec 2013
Posts: 2,971
Fort Worth, Texas
clinebarger Offline
clinebarger  Offline

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Fort Worth, Texas
I've always had Flywheels "Ground", A Lathe-bit will ride over the hard spots......Just my opinion!


2001 Chevy Camaro L92/4L80E
2006 Chevy 2500HD LBZ/Allison 1000
2010 Toyota Corolla 2ZR-FE/U341E
2000 Toyota Avalon 1MZ-FE/A541E
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5008442
02/11/19 11:28 PM
02/11/19 11:28 PM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

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Reunion Island
If life allows us to spend some big money in cars, this toy is gonna get some uprated parts (because anyway suspension would be dead, every rubber parts, etc.)


‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: clinebarger] #5008444
02/11/19 11:32 PM
02/11/19 11:32 PM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

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Reunion Island
Originally Posted by clinebarger
I've always had Flywheels "Ground", A Lathe-bit will ride over the hard spots......Just my opinion!

I thought that, but then going over with the needle tip dial gauge (how do you people call that device?) shown virtually nothing bumpy. But that was one really BIG lathe, could have put myself in it

Last edited by Superflan; 02/11/19 11:33 PM.

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5008453
02/12/19 12:02 AM
02/12/19 12:02 AM
Joined: Dec 2013
Posts: 2,971
Fort Worth, Texas
clinebarger Offline
clinebarger  Offline

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Posts: 2,971
Fort Worth, Texas
Originally Posted by Superflan
Originally Posted by clinebarger
I've always had Flywheels "Ground", A Lathe-bit will ride over the hard spots......Just my opinion!

I thought that, but then going over with the needle tip dial gauge (how do you people call that device?) shown virtually nothing bumpy. But that was one really BIG lathe, could have put myself in it


Dial Indicator, I guess if the lathe was big enough & you plunge the tool holder/bit head-on into the material, Maybe? Surfacing usually requires a consistency in the material being cut.
I machine a lot of automatic transmission pistons, pressure plates & drums, But am in no way a "all knowing" expert on running a lathe!


2001 Chevy Camaro L92/4L80E
2006 Chevy 2500HD LBZ/Allison 1000
2010 Toyota Corolla 2ZR-FE/U341E
2000 Toyota Avalon 1MZ-FE/A541E
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5008558
02/12/19 07:43 AM
02/12/19 07:43 AM
Joined: Apr 2015
Posts: 485
Reunion Island
Superflan Offline OP
Superflan  Offline OP

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Posts: 485
Reunion Island
Yeah it was a very big lathe.

Well, the car is running!

It was a great experience to learn car mechanics.

Thanks to the crowd here at BITOG, friends, brother, and brother's friends for making all this possible, all in a short delay with more than good results ! And parents for keeping my 3yr old son entertained while I do those repairs

Keep wrenching, learn something.

Bonus: old parts pics

20190212_114154.jpg
Old Friction disc

20190212_114146.jpg
Other side

20190212_114211.jpg
Old pressure plate

Last edited by Superflan; 02/12/19 07:46 AM.

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 258000 Km, running on WVO
Wife's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 148000 Km
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