New clutch problems

So Im most of the way thru a 5 speed swap on my 99 extra cab 3.4l. Got the transmission installed, new aisin master and slave cylinders, luk clutch kit and flywheel. Got it installed and started engine, wouldn't go into any of the gears, shut the engine off, can shift thru every gear no problem with engine off so I shifted into reverse, started the engine and let up on clutch pedal and about an inch off the floor it started to go backwards. I quickly pushed the clutch pedal back to the floor and it idled really low and I could smell the clutch burning. Re bled the clutch hydraulics thoroughly, no air came out, tons of fluid, clutch fork has good throw when pushing/releasing clutch pedal. So I restarted the engine, same thing happened. I pulled the transmission out again, and there's a couple things I noticed, the throw out bearing has grease coming out of it, and according to what I've found online, I installed the clutch disk backwards. It's a luk clutch kit, 16087 I believe is the part number, and according to what I've found the clutch disk is supposed to be mounted with the flat side facing the transmission. It is stamped on the flat side as flywheel side, but I decided to follow the fsm as I figured it was stamped wrong. So I went to flip the disk around to try it the direction the disk is stamped, but I noticed the hub/splined section of the disk appears to be slightly crooked in the disk. Not a lot, but it is definitely not completely straight inside the disk. Could I straighten it somehow? Also, the grease coming out of the throw out bearing, is this a problem? Was a good amount of grease for only be started a handful of times and really only idling.

 

What a pain. Unfortunately you're not the first of last to go through this. Aisin also marks transmission side on their clutches which frequently throws people off when installing on a 3.4. The splined section of the disk should be perfectly straight and I wouldn't risk trying to straighten it. I wouldn't expect to see more than a very small amount of grease coming out of the bearing. You might want to return that kit for those two reasons alone. Luk makes pretty solid kits so hopefully this was a one off.

 

Well, apparently this disk is marked correctly, but I installed it how the fsm says to install the disk, which is protruding side of the disk goes towards flywheel. I was thinking the same thing about not trying to straighten it, just figured I'd ask. Thanks for the reply.

 

In that case then I am 99% sure that you did install it correctly. Hopefully others can chime in and confirm. Are you sure the original problem wasn't due to the crooked splined section?

 

Ide make some calls to the clutch manufacturer, the in & out game bs sucks, not an easy job to begin with...
If the t/o bearing came with the clutch, maybe they can warranty a new disc & t/o bearing...
My guess would be install it as it was stamped, cuz obviously the other way didnt work....
most importantly get clarification from the clutch manufacturer.....

 

I just confirmed that the side with the springs protruding does face the flywheel which is what it shows in the FSM. That crooked spline section would cause the disk to also sit crooked which would never let the clutch properly disengage.

 

that seems wrong to me....
Never done a toyota clutch but clutches is what I did, 1000's of fords....

 

Can you even flip the disc without the hub & springs making slight contact with the flywheel side?

 

It's opposite on the 3.4.

 

More crap parts, it is plaguing all areas of the US. It is to the point where I am telling the people whos cars I work on that if you need it asap, take it somewhere else as I can not gurantee a completion time due to parts. 3 week wait for an B1S1 O2 sensor for a 2002 Maxima, cmon...

 

maybe the case, as stated I wasnt a toyota tech...
I still say get with the manufacturer.
Regardless what FSM says, that "flywheel side" stamped on the disc may be there for a reason & not an error....
Or get a factory toyota clutch & be done with it.....

Ive always recommended & only used ford clutches, they were the best option out there with no guessing games, great warranty, always worked, vs some parts store option....

 

Totally understandable. I think the 3.4 is the only truck on the planet that does it this way. There's a number of Tacoma and 4runner threads on different forums where people ran into this issue.

 

Ide still call clutch manufacturer to get clarification.
I have no idea who LUK is but maybe theyre doing things different to avoid confusion, or cause more of it....
He installed the clutch with the offset facing forward & that obviously didnt work for whatever reason...

 

If you look in the Toyota fsm, it says to install it with the offset facing the flywheel, however, this disk was stamped opposite, I figured it was an error so I installed it the way the fsm says too. I just recently found a video from the manufacturer stating that the disc is, in fact, designed to be installed with the offset facing the transmission. I also found a video on YouTube, a mechanic installed this same kit and installed it with the offset facing the transmission. So apparently I did install it backwards. I can't just flip it around though because the splined hub on the disc is not straight, it is slightly crooked and I'm not sure if it's safe to reinstall. Also, the throwout bearing appears to have a bad seal because grease was already coming out of it.

 

I'll post a picture of the splined hub part of the disc, you can see what I'm assuming is a bushing of some sort, you can tell from looking at it that it isn't straight.

 

So im somewhat correct...
I did say maybe the clutch manf made it different & the offset is suppose to face back, flywheel side is actually the flywheel side...
You bent whatever it is, maybe send them pictures...
maybe you can get a new free disc from them before re-installing it...

I think putting the disc in the way the clutch manufacturer wants you to is the way....
BUT, ide still talk to a live person so its not an in & out all over again...

 

I see the offset splined center, IS there any play in that or is it stationary & solid????
I would not put that back in till you talk to them & they see a pic...
If theres zero play.
Not tell them you ran it flip flopped...
But get clarification still in regards to orientation also

I dont like the off centered splined hub!!!

 

I don't see how you could have installed it backwards and not made contact.

 

Backwards or not, if not installed as it was designed to operate will cause improper operation, no release correctly & drag....