2nd gen manual transmission fix

Why would you pay dealer funds to install aftermarket parts $$$$$$$$$$$

The OEM LUK clutch as well as the OEM Aisn are both available on line cheaper with excellent warranties than what you will pay at the dealer

Try calling around to a couple transmission shops for some quotations before you shed your hard earned cash

 

Just received an Exedy "OEM" clutch kit from RockAuto for a bit cheaper than Aisin; I wonder how it compares.

 

According to the centerforce website there clutch requires a tb that is compatible with the aisin pp. Anyone have any idea why this is? The aisin pp looks identical to a stock one.
There recommended tb measurements are
Specifications
Major O.D.
1.835 - IN
I.D.
1.398 - IN
Depth/Height
1.900 - IN
Clutch Masters does not list any dimensions for their hydro tb.

 

I think it's to insure the TOB does not interfere with the centrifugal weights.

 

How’s the dealer gonna feel about deleting the oem slave cyl setup ?

 

The OEM Aisin pressure plate and LuK pressure plate do not have the same height, which is why the release bearings are different between them.

Jeff

 

These are going in tomorrow, wish me luck!

 

I will call around and see what i can find locally (St. Augustine, FL) but for what a few dollars per hour difference from the dealer's $115/ hr and a local "shop's" $90-$105... ehhh... for the few hours this will take, I am inclined to just have the peace of mind that a trained Toyota master mechanic will do just as if not better than a local shop.

I can take in any aftermarket parts to this dealer and they will install no questions asked....

Isn't OEM Aisin anyway??

 

My local dealer's Master Mechanic (Beaver Toyota, here in St. Augustine, FL said "no problem"). They will charge me 2.5-3 hours of labor to do the job. That would be in addition to their standard labor for a new clutch installation... I will probably haggle that down a little bit.... IF i end up having them do the install. Which at this moment i'm leaning towards doing. But that is still TBD....

 

What brand clutch (package) is that? ClutchMasters or ??

 

he got a URD clutch and i think their heavy flywheel

 

After more investigation, I believe that there’s a problem with the step of my flywheel.

Kevin at CM told me that it should be .040”. So, that’s what I told my machine shop to cut it to. When I got it back, I simply bolted it back to the crankshaft and continued my installation without checking that they’d cut it to my spec. I suppose that was my mistake. Trusting a machine shop.

So, yesterday, I called the machine shop I used and explained the situation. I asked them point blank if they’d cut my flywheel to the .040” step that I’d requested. He then replied with an explanation of how they do them. They basically measure it before and duplicate the existing step. Which is probably fine in “most” situations. Not mine. I had explained to him when I sent it down there originally that I’d suspected that it had been cut wrong in the past. Well, I won’t know for sure until I pull the damn trans out again, but, I’m pretty sure that the guy on the phone at the machine shop and the guy actually doing the machining are not communicating well. End result: Jake gets to do the job twice.

So, I guess what I’m saying is that you need to make damn sure that your flywheel is cut right before putting the thing together.

Use new OE bolts to secure the flywheel to the crankshaft btw. They are stretched after use and should not be re-used. New bolts are torqued to 22ft lb and then turned an additional 90°

 

I'm cautiously watching this thread.

Both LUK and Aisin were originally the OEM suppliers for the clutch assemblies in our truck. That is the reason the parts manuals from about 2005-12 originally gave the choice between a "Type A" and "Type B" clutch. Because of excessive warranty claims where the LUK clutches were installed they were dumped in about late-2012 as a supplier and Aisin clutches were then the only ones installed during production and available for replacement parts.

The reason I am cautiously watching is because when the PD&M sleeve was first released it too was all the talk of being a permanent fix....until some problems started being reported once the miles started racking up. But I have not read of widespread issues with it though, and I still have mine with no complaints, so I would like to see some miles racked up on the CM hydro fix before I jump in.

Question for those who have done the hydro bearing: does the CM hydro bearing ride on the fingers of the PP all the time once if installed according to instructions? Has someone pulled the inspection plate and taken a look-see? Reason I ask is their site description seemed a bit vague to me when I looked sometime back so perhaps I missed something. I suppose I will call them next week to get some more info...

 

it doesnt ride on the PP fingers. thats why there is an airgap for the CM bearing. on the Tacoma setup, its fixed and you dont have to set it and with their universal options, you have to use shims to set the airgap correctly

@406cruiser correct me if im wrong on this info above

 

^^^ Thanks. I just did a quick visit to the CM site. From their description:
"The 6-speed manual RA60 or RA61 are great transmissions from Albins but you wouldn't be here if they were 100% perfect."

Hmm. Albins? Lol.

I also noticed that the other Toyota kit listed for a different Toyota transmission has specific instructions for setting the air gap but for the RA60 that block has been edited to eliminate the air gap instructions and just says installation instructions.

The proof will be from those who have done the install so I imply nothing.

 

ive installed it and havent had any issues and i probably have one of the most odd ball clutches since its not made by urd anymore. I have their twin disc clutch. the only thing i had to do was adjust the clutch pedal.

 

My concern with simply adjusting the pedal side to adjust the release point is that you may put the master cylinder into a position that would prevent it from hitting the suction port for the fluid reservoir in addition to always pressurizing the system, either that or having excessive freeplay.

It would be much more ideal to have some sort of mechanical adjustment on the slave side of the equation if the bearing isn’t meant to maintain contact with the pressure plate.

Jeff

 

URD stage 3 and URD heavy flywheel

 

The PD&M sleeve was for sure a much better solution then the factory setup since it reinforced the aluminum quill with a steel sleeve. That was initially going to be the solution I was going to end up going with until I kept doing research and found that people were having massive failures with those kits as well (entire quill snapping off). Probably a rarer situation then the OE setup but still wasn't my first choice at that point. Ideally this whole issue could have been avoided had Aisin manufactured the transmission with a bolt on steel quill or snout like a majority of transmission out there have.

I'm putting on miles as quick as I can lol, about 2800 miles in and zero issues. I have taken the inspection plate off and everything still looks brand new in there, zero signs of wear to the piston.

Yes the TOB still technically rides on the diaphragm, there is no way that it couldn't. However compared to the OE setup that preloads the TOB against the fingers, the CM setup is just riding on the fingers with zero pressure. When I approached CM about this fix, I never intended or expected to have a solution that would eliminate the possibility of a TOB going out down the road. I mean there's only so much you can expect out of a bearing that spins thousands of RPMS for several thousands of hours runtime. My main goal with developing this kit with CM was to eliminate the possibility of catastrophic failure with the quill/snout or pivot ball. I do feel however that the TOBs should last longer with these kits because of the fact that they aren't being preloaded against the diaphragm.

Ha yeah Albins, that's definitely a typo! Aisin is the manufacturer of the transmission. Yes this kit has been specifically developed to work with OE stack height clutch kits. CM developed a spacer specifically for these transmissions where as a lot of the other hydraulic release bearing kits for other applications were made with a more universal spacer setup.

As I mentioned above, yes the TOB does ride on the PP fingers. The air gap is setup to allow the bearing/piston to self adjust with the PP as the clutch wears. @gearcruncher has explained it perfectly in previous posts on this thread.

 

How did install go? What's your thoughts on the stage 3 with heavy flywheel?