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Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005777 02/09/19 01:56 PM
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eljefino Offline
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well done!

Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5005783 02/09/19 02:03 PM
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mk378 Offline
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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
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KrisZ Offline
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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
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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
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Superflan Offline OP
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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, 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] #5005994 02/09/19 06:16 PM
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supton Offline
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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, 189k, hers
2010 Toyota Tundra DC, 4.6L/6AT, 153k, ours
1999 Toyota Camry LE, 2.2L/4AT, 211k, his
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5006793 02/10/19 01:22 PM
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Nice work!


2007 BMW 335i n54 205,000 miles, lubricated by whatever is on sale
Re: Wife's RAV4, burnt clutch, DIY [Re: Superflan] #5008351 02/11/19 09:05 PM
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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, 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] #5008359 02/11/19 09:11 PM
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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
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Superflan Offline OP
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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, 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] #5008436 02/11/19 11:08 PM
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clinebarger Online Content
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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
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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, 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: clinebarger] #5008444 02/11/19 11:32 PM
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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, 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] #5008453 02/12/19 12:02 AM
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clinebarger Online Content
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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
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Superflan Offline OP
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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, 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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