my boring clutch rebuild thread

[Previologist]

Ugh, wish i hadn't researched it further, or maybe I am lol. Now I also question whether its on upside down or not....https://www.toyota-4runner.org/3rd-gen-t4rs/300768

I have it installed like #2 in that thread.

But the ad photo suggests I have it upside down. Toyota 4Runner, T-100, Tacoma, Tundra 3.4L 5VZ (1995-2004) Japanese Clutch Release Bearing - BRG902

That makes more sense, and would explain why neither way I tried seemed quite right. I probably should've paid more attention when I took it apart, huh.

I have it under the truck partly jacked up, almooooooossst ready to install. I think I need to flip that clip over. Dangit. i better take a couple Effitol.

 

[Previologist]

Done, flipped it over and I'm now positive that #1 in the pic is the way it was originally done at the factory. I can tell by the wear marks on the underside of the fork tines. There is no way the wear I saw could be made by method #2

#1 is the way mine was installed at the factory.
#2 is not, but ironically, might actually work, and I think some people have installed them that way like I almost did.

cou

 

[Previologist]

Done, flipped it over and I'm now positive that #1 in the pic is the way it was originally done at the factory. I can tell by the wear marks on the underside of the fork tines. There is no way the wear I saw could be made by method #2

#2 ironically, might actually work, and I think some people have installed them that way like I almost did.

 

[Previologist]

What a fun day! While you were out boating, biking and barbecuing I was wrestling, wiggling, pushing, shoving, shifting, pulling, lifting, lowering, twisting and turning and tilting that tranny most of the day, and I just could NOT get it on that last couple inches. It was hanging up on something I couldn't see, even after I had several of the bolt holes lined up with wooden dowels. Finally, in desperation, I laid on my back under the bell housing and pushed up while pushing the tranny forward with a knee and finally it cleared whatever and the tranny shaft penetrated the plate springs. Still have about an inch to go.

I got the 2 left side bolts started and one on the right side, but the other one was not cooperating so I'm not out of the woods yet. But I see a clearing.

 

[brillo_76]

Mostly they slide together if everything is lined up.. I wonder if that plastic alignment tool has your clutch alignment in? Did you try to slightly turn the shaft to see if it goes the rest of the way?

 

[JohnMc]

With only an inch to go you probably have the input shaft splined into the clutch disc. You're probably to the point where the end of the input shaft needs to find the pilot bearing. it just has to be aligned nice and square, and this is where the alignment tool was supposed to get the clutch disc lined up properly with the pilot bearing.

But just try making sure it's lined up properly, the same gap around all sides of the bellhousing, top, bottom, left, right.

 

[Previologist]

I didn't have any trouble getting it all the way in today. I could tell with fresh eyes looking through the wheel well that I just had to raise the TC an inch to get the upper side bolts in (I thought one was started yesterday, but it wasn't). Then I pulled it the rest of the way in with the 4 side bolts.

Then the fun started trying to do the top bolts. I got one torqued down but it took forever getting the extensions positioned by myself. What a pain. It's really a 2-person job. Hopefully get the other top bolt in the morning and then the worst will be over. Right? lol

 

[phattyduck]

I didn't have any trouble getting it all the way in today. I could tell with fresh eyes looking through the wheel well that I just had to raise the TC an inch to get the upper side bolts in (I thought one was started yesterday, but it wasn't). Then I pulled it the rest of the way in with the 4 side bolts.

It is sometimes a dangerous to pull in the transmission with the bellhousing bolts - if it is out to far, you can crush or break things in there and not feel it since the bolts can apply a LOT more force than you might think.

Better to wiggle and push things manually as much as possible (having bolts started to aid this is totally fine though).

-Charlie

 

[Previologist]

It is sometimes a dangerous to pull in the transmission with the bellhousing bolts - if it is out to far, you can crush or break things in there and not feel it since the bolts can apply a LOT more force than you might think.

Better to wiggle and push things manually as much as possible (having bolts started to aid this is totally fine though).

-Charlie

NOW you tell me. That's a day too late lol.

But I am not too worried. I have pretty sensitive hands, and used only a stubby to tighten all 4 side bolts. I felt nothing resembling unexpected resistance, and heard no ominous sounds. But now I know.

I was more worried about damaging the bolts by too much wriggling after they were started.

 

[brillo_76]

Glad you got it... How I get the Bell housing top bolts is use the transmission to tilt it down. I let the transmission down some after i get some of the side bell housing bolts in. That way you can get the top 4 ones. If you have the side bolts in first. Then using a jack you let the transmission down in the back some until you can get to the top bell housing bolts. Once in and tighten then torque those 2.. Jack it back up and torque the rest. If the transfer case off make sure those bolts are all in place as a few can be tricky once the transfer is on.

I am sure you can get this now.. Good job.

 

[Previologist]

Uh-oh. Danger, Will Robinson.

The clutch fork doesn't feel right. Granted I don't know what it should feel like but it doesn't feel like it did before I installed it, that's for sure. It just kind of clanks when I move it back and forth. Maybe the slave applies a lot more pressure but I don't want to force it. Tell me how I can make sure its working properly before I go further.

I suppose this might be perfectly normal if the throwout bearing is now snug up against against the diaphragm springs, but it gave me that sinking feeling....

 

[brillo_76]

Uh-oh. Danger, Will Robinson.

The clutch fork doesn't feel right. Granted I don't know what it should feel like but it doesn't feel like it did before I installed it, that's for sure. It just kind of clanks when I move it back and forth. Maybe the slave applies a lot more pressure but I don't want to force it. Tell me how I can make sure its working properly before I go further.

I suppose this might be perfectly normal if the throwout bearing is now snug up against against the diaphragm springs, but it gave me that sinking feeling....

Do you have the slave cylinder bolted on and how does the pedal feel? Did you have the clutch fork snapped on the pivot point?

 

[Previologist]

Do you have the slave cylinder bolted on and how does the pedal feel? Did you have the clutch fork snapped on the pivot point?

No, neither of those. I just panicked when I fiddled with the clutch fork by hand. I only have the tranny bolts all in and torqued, nothing else connected. I'm sure the fork is still mounted on the pivot. I panicked because I couldn't feel the release bearing sliding back and forth like I could with the tranny out. But after thinking some more I calmed down, and figured that is probably normal when its installed. But confirmation would be nice.

But then...my overthinking brain started wondering if I put the clutch disc in the right way. If I am to believe some older threads here, that state the springs should go IN on the v6 3.4, then I did it wrong. But I am not convinced of that. I had no trouble getting the pressure plate on, and I definitely placed the T/M side OUT. But according to the threads that is wrong, but don't believe it. Maybe its wrong with the factory pressure plate but I can't believe Aisin has been marking their disc and pressure plate kits wrong all these years.

3rd gen 5vz AISIN clutch nightmare F-up

This pic shows a disc the wrong way, and the pressure plate won't even go on. I had no such trouble.

Maybe hooking up the slave and testing it should be my next step? I'm in no hurry because the rest of my parts don't come until later next week, so I can afford to be careful or even drop it again if I have to. But I will need a darn good reason to do that, lol.

 

[brillo_76]

The clutch can go in the wrong way. The Factory Service manual shows this the proper way. As that is correct if wrong it won't go together properly.

 

[Previologist]

The clutch can go in the wrong way. The Factory Service manual shows this the proper way. As that is correct if wrong it won't go together properly.

I don't have an FSM for the 4runner but I found the page for the Tacoma
here 3.4 V6 Clutch Orientation - Important! | Tacoma World

and it looks like my tranny has to come out again.

I was hoping it would. This has been so much fun I really wanted to do it again. :target::israel::clap2::mod:

 

[Previologist]

Looks like Marlin had theirs marked wrong at one time too. Marlin Clutch Disc Orientation - stamp on disc does not agree with FSM

Its really inexcusable that Aisin is still marking them wrong for this engine, at least 7 years after the internet knew about it.

 

[brillo_76]

Looks like Marlin had theirs marked wrong at one time too. Marlin Clutch Disc Orientation - stamp on disc does not agree with FSM

Its really inexcusable that Aisin is still marking them wrong for this engine, at least 7 years after the internet knew about it.

These clutch kits are for many vehicles. The FSM shows the clutches go in backwards on the 4 runners. I suspect you didnt take any photos when taking the clutch apart. Marlin used to have the FSM photos with their clutch kits showing and warning of this issue in the 4 runner.

I included a photo from FSM.. I hope this helps you. I know I remember my mistakes more then my success....

 

[Previologist]

I am always happy to take credit for my many mistakes, but I won't take the rap for Aisin. If the disc markings don't apply to ALL vehicles, they need to tell people that. And I sent them an angrygram telling them so.

And someone might think well, you should have had the FSM available then. But I thought I did. I made sure I downloaded the FSM (I believe from this site) before I started, but after I started the job I discovered that the one I downloaded didn't have anything on clutches or manual transmissions.

No worries, this has been such fun to do once, why not do it again! Maybe I'll do it 3 times, just for fun! I just hope my HF jack is up to the task, because one of my admitted mistakes did cause it some damage.

 

[brillo_76]

Ok.. But Aisin is not a fault. That was my point. They are not going to put instructions in for every vehicle this clutch fits. The 99.9% it goes in the other way. Only the V6 5VZ-FE it goes in the opposite way that I am aware of.

Don't take responsibility for not paying attention when taking the clutch apart nor verify how things are. Doesn't matter to me you just do it again and again and again until it in properly.

You are not the first person to put the clutch in wrong and you will not be the last. Things happen not a majorly big deal. This is how we learn or how I do. I learn more from mistakes then not myself.

I am sure you get the clutch back together.. I have faith..

 

[Previologist]

It didn't take long to get it out this time. Next time will be even quicker. I hope there is no next time.

The only thing I found askew other than the backward disc is one of the pressure plate lock washers had opened up and spread out to an unsafe degree, and I failed to notice that when I torqued it to 14 ft/lb. So it's probably a good thing I put the disc in backward, because that washer would likely have failed eventually and the bolt would have been very loose. So I just need to find a washer. Think I will also buy a new torque wrench just to be safe. I calibrated mine last year but I doubt my calibration was perfect.