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Re: Wife's RAV4, burnt clutch, DIY [Re: KrisZ] #5004772 02/08/19 11:48 AM
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DoubleWasp Offline
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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
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Superflan Offline OP
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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, 262000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), FACTORY FILL, 6000 Km
Backup's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 158000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Miller88] #5004883 02/08/19 01:50 PM
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bullwinkle Offline
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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
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KrisZ Offline
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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
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mk378 Offline
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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
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Superflan Offline OP
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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, 262000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), FACTORY FILL, 6000 Km
Backup's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 158000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5004942 02/08/19 02:53 PM
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benjy Offline
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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
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JC1 Offline
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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-30 Valvoline White Bottle/Fram Ultra Filter
1997 Honda Civic CX 5w-30 Shell Conventional/Fram Ultra Filter
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005002 02/08/19 03:56 PM
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Lolvoguy Offline
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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
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Silk Offline
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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 - Penrite VTwin 20-50
2005 Nissan Expert - 5W-30 Castrol Edge
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
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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
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Superflan Offline OP
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New parts

20190209_091747.jpg20190209_092422.jpg

‘01 Peugeot Partner 1.9 D, 5W40 A3/B4, 262000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), FACTORY FILL, 6000 Km
Backup's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 158000 Km
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005624 02/09/19 10:52 AM
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Audios Offline
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Wheres Extra EU?


2002 VW Golf TDI-T5 10/30
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
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mk378 Offline
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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
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Superflan Offline OP
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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, 262000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), FACTORY FILL, 6000 Km
Backup's ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 158000 Km
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