Clutch dramas

[wagonist]

I've been battling clutch issues in my car for a while.
It doesn't fully disengage, so much, that now its a bit worn, I've been getting around by rev matching during gear shifts & not using the clutch at all.

I've redone the master & slave cylinders.
The only thing left now is to pull the box out & check the clutch parts themselves.

It appears from my EPC that the pressure plate, release bearing & spigot bearing are the same as an SW20 MR2, but the clutch plate itself is a unique part number for the FWD Toyota diesels only.

I have a feeling if the clutch plate I installed was wrong, maybe it's the thickness that is different.
Is there a way to find out what thickness clutch plate I need? A toyota one runs at $350 for the plate alone, ex Japan.

[allencr]

Does this have a stepped flywheel- its friction surface & pressure plate mounting surface are not the same?

If not & has a flat surface, a rule of thumb is for the disk's thickness to be twice the pressure plate's distance between its friction surface & mounting surface.

If it has, it'll have to be mounted together, minus disk, to measure it.

[wagonist]

I'm pretty sure that the flywheel has a flat surface. I vague remember that there were only press in dowels in the way of machining it (but this was 115 000km & 5 years ago )

So, once the lot is out of the car,

• rebolt the pressure plate to the flywheel without the clutch plate installed,
• measure the distance between the pressure plate face & the flywheel,
• then double that to get the required maximum thickness of the clutch plate?

[Cuzzo]

Im having the exact same problem. Im thinking its the clutch slave cylinder rod not being long enough, however im trying to diagnose this tomorrowIf you find the problem could you update the thread? Thanx

[wagonist]

Originally Posted by cuzzo

Im having the exact same problem. Im thinking its the clutch slave cylinder rod not being long enough, however im trying to diagnose this tomorrowIf you find the problem could you update the thread? Thanx

You'll be working on it at your place? I've got tomorrow off. I can pop round if you want.

[wagonist]

I've had this drama ever since I installed the clutch, though nowhere near as a bad as lately (obviously as the clutch has worn it's gotten worse)

[Cuzzo]

Yeah i will be however im not sure what time. I have to go out a few times. I will be on here though when im home so if your online i'll pm you.

[LeeRoy]

Could also be a broken or bent clutch fork.

Your running standard transmission etc arent you? or was this originally auto?

[allencr]

No, that was only if it maybe had a stepped flywheel and a necessity for a recessed.


1. Hold pressure plate in hand, friction surface facing up.
2. Place disk on it.
3. Sight/look along the pressure plates mounting surface, comparing it to the nearby disk, to see that the middle of the disk is roughly level with it.

[wagonist]

OldCorollas had kindy found some links (in Russian) for an Exedy site that listed a clutch plate that matched the Toyota part number that's supposed to be in mine.

Today I went upto one of our sponsors shops, B&R Brakes, to get some info.
He actually found a listing for my car, Diesel & all , & can supply a complete kit for less than half of what Toyota wanted just for the clutch plate...

Now I've just gotta find another car to use for a day so I can pull the engine & box out of mine & take all the bits everywhere to get sorted.

[Cuzzo]

I just went to b & r myself in blacktown and order a new master cylinder. Michael thinks that could be the problem from my jambed on slave cylinder rod. He thinks that the relieve valve isnt working correctly inside the master.

[wagonist]

Cool, I hope that works out for you.

[Cuzzo]

Well it didnt work for me.

Im having to pull the box out now.

I replaced the master cylinder and bled the clutch however the car still moves when i have the clutch in and i give it a rev.