Ra60f help

Hey guys I'm having some issues with the trans in my 4runner. (Ra60f) I installed a new clutch when doing the install and it chatters like a bitch when starting out. Chatters under load (going up steep hills in first) for some reason more when turning right than left. And when going over bumps under load. I'm also experiencing a leak where the transfer case mounts to the transmission after replacing all seals. I've read multiple forums about this transmission and haven't found many answers. Thank you

 

Hope I can help you out with this problem, I am familiar with how frustrating clutch and transmission issues are (had mine out and in 4 times now).

Here are some questions to make sure I understand, and then I can get to some ideas about what might be going on.

1. Is this an OEM replacement? If not, is it a cheaper option? Or, is it a more expensive "performance" clutch?
2. Do you get vibration in the pedal? If so, when, i.e. at idle, under load, when pressing the clutch pedal, etc.
3. Where is the clutch engagement in terms of approximate pedal travel (50% of travel from floor, for example)
4. When you say it chatters under load, this meaning it chatters when you open the throttle, i.e. it's not engaging and/or slipping even when the pedal isn't pushed?
5. Is the transmission harder or easier to select gears after the work was done?

When it comes to replacing the seals, they can be difficult to install properly. It can be somewhat of an art. All I can think to tell you about that is you'll probably have to replace them again.

 

Did you have the flywheel resurfaced?
Was the engine/transmission/transfer case mating surfaces clean before reassembly?
You may also check that the locating dowels are properly installed and the bolts are tourqed to spec. It sounds like you have an alignment issue between the engine/transmission/transfer case (not the suspension).

 

The transmission is from a 09 tacoma with 110k miles and the flywheel did have some hot spots, it was not resurfaced. I have an oem replacement clutch kit. The mating surfaces are all clean. And aligned perfectly. All seals are replaced. Previously I used the input shaft seal from a fj cruiser transfer case and it leaked like a bitch but now I'm using the correct tacoma one. I think the leak may just be residual oil now because my levels are all perfect. The clutch engages at about 60 percent of releasing pedal. From your guys response it seems like resurfacing or purchasing a new flywheel is the best way to go and just quadruple checking all my surfaces, alignment, and torque.