HELP! 2008 i4 flywheel minimum thickness - EXPLODING CLUTCHES!

Long story short, clutch wore out after about 150,000 kms. Installed a new Aisin clutch and resurfaced the flywheel about 5,000 kms ago. Clutch blew up again last week - see pics. If you notice the abrasion on the springs and the way the clutch broke (center piece essentially torqued so hard it sheared all the way around on the inside of the contact area).

My mechanic is pushing the exact same parts on me. My friend (also a mechanic but lives far away) thinks he turned down the flywheel too much and the clutch is making contact with the flywheel bolts which created enough torque to explode the clutch. I had the shop pull out the tranny again so we can measure the flywheel thickness but would like to know what it should be at a minimum so I don't get the run around. Help!!!

Could it be anything else?

 

If the ware on the clutch plate is from hitting the fly wheel bolts is because it was installed backwards. I'm surprised you could even get it into gear.

 

theoretically, if the flywheel is too thin, could that cause the abrasion shown on the center springs and consequent snapping of the clutch metal? (basically the whole center piece popped out)

 

anyone know the minimum flywheel thickness for a 2008 i4 4x4 5 speed?

 

i think they are the engine side

 

I'm gonna go with the clutch disc was installed backwards. You would have to grind the flywheel down quite a bit to get it thin enough to do damage like that

 

take a picture of the flywheel . if the machine shop cut the flywheel face down without cutting down the center , even a clutch disc installed correctly can rub . The torsion springs rub on the flywheel retaining bolts . I dont beleive a disc could be installed backwards in a tacoma .The miñute the vehicle starts you would be moviñg at engine speed because the clutch disc wouldnt pull away crom tbe flywheel enough to rdalease the energy of the engine.

I am wonderinģ if the op heard any unusual noises when the clutch applied and rèleased foŕ the 5000 miles that it lasted
A good machine shop will write down the before and after thickness of the flywheel so the installer knows what flywheel shims to use to keep factory hydraulic travel within spec . overall flywheel thickness is not yoùr issue here . With only 5k , you should have warranty providing your shop installed correctly . If you look at all tbe parts you can see any shortcuts that were taken. If the shop sold.you the clutch , they are seeking warranty from their parts suppllier for the identical parts

 

Hub (the part which potrudes from the disk surface) should be facing towards the transmission. Flat side towards flywheel.

Unless you have a clutch which comes with a special flywheel, and the manufacturer states it clearly that the hub faces the flywheel.

 

Secondly, that factory clutch is junk. Trash even. Already been reported by the SAE to have a design flaw which causes separation of springs from the hub. Toyota doesn't care.

The plastic pieces at the ends of the springs are known to break. When that happens, the spring falls out and causes all sorts of issues.

Yes, I have dealt with this personally as well. At minimum, get the Excedy OEM replacement. More robustly built and doesn't have the plastic end isolators.

 

I have seen plenty of clutches installed backwards, which by the looks, this one possibly was as well. Use your best judgement if you can or cannot reuse it, facing the proper direction.

 

2nd gen flywheels are a little more costly than a 1st gen. But I think when you add up the problems you've had. Wouldn't it be wise to just buy a new one?

 

I drove for 5000 kms with the clutch disc backwards then. Is that even possible?

 

If the hub fits in the opening of the flywheel, yes.

 

Sonhovagun. Going to the shop now - keep you posted.

 

The clutch disk reaction spring hub fits inside of the clutch cover in 99% of any install. There is nothing inside the the cover that could have caused that damage had it been installed properly. The clearance between the crank bolts and the disk would mean that the fly wheel would have had to been cut a 1/4 or more and then the damage would have been on the other face of the disk had it been installed right way around. It's backwards I would show it to another shop before I went back to the first one and see what they have to say.