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News > Projects > Project ST2GT4

Mod: Clutch Install/Upgrade (Pt 1 of 10)

Modification Type:
Performance

Difficulty of Install/Modification:
Moderate

Preparation And Install Time:
5 hrs

This clutch installation article is aimed for the 4AFE and 7AFE engines (Celica ST).  The 5SFE (Celica GT) and FWD cars that have the 3SGTE swapped in can use this article as a good guideline.  When it comes to changing the clutch for the 5SFE or the 3S-GTE, the only difference is the location of the starter.  Everything else is very similar.  When it comes to changing the clutch, there are five main things we need to remove:

  1. Drive axles (or drive shafts)
  2. Starter
  3. Engine Mount
  4. Crossmembers
  5. and the transmission itself

 

Stuff you'll need:

  1. Breaker bar
  2. Gunk Liquid wrench
  3. Long sockets for your 3/8 ratchet (17-28mm!) or for the breaker bar.
  4. Bucket/Pan for transmission gear oil.
  5. Thick Flat screwdriver
  6. Phillip screwdriver
  7. A labeled tray for all the nuts and bolts
  8. The Best Hi-Temp Grease you could find.
  9. 4 bottles of APL GL-5 (75 W90) Gear Oil.  Well...as long as it's 75 W90.
  10. Two spare hydrolic jacks OR 1 ton transmission jack (highly recommended)
  11. An extra hydrolic jack and rope (requires strut tower bar) to support engine OR Engine Hoist (highly recommended)
  12. clutch disc
  13. clutch cover
  14. clutch alignment tool
  15. throw bearing
  16. 2 cans of a good Engine cleaner
  17. 3 cans of Brake cleaner of a reputable brand (prefferably CRC).
  18. 250 Grit/500 Grit Sandpaper (in case flywheel cannot be resurfaced from a reputable machine shop)
  19. Oil funnel with 2 ft flexible extension.
  20. 2 Cotter pins (will be illustrated later in this article)
  21. 2 Hitch pins to replace the shift control arms (just in case).  This will be illustrated later in the article.
  22. A partner (required if you don't have a transmission jack like the one below)

So yes...if you can, please try to get this.  It will definitely make your clutch install 10 times more fun.

Figure 1 (courtesy of harborfrieght.com)

And so we begin by showing you some shots of the clutch we're going to install. 

Figure 2 (this is a stage 1 clutch.  It's a bit better than OEM but not completely performance)

Figure 3 (clutch cover)

Figure 4 (alignment tool and throw bearing)

Now that we're done looking at the clutch goodies.  Let's get back to work.  The first thing we need to do is disconnect the battery and remove the air intake pipes.  If you have a short ram intake like the one below.  There will be less work.  For everyone else, expect to deal with the cumbersome air box.  On another note on Figure 5, you'll see that the bigger oval/circle is a bolt attached to some hydrolic line.  That hydrolic line is responsible for engaging your clutch.  Remove it?  Yes.

Figure 5

Detach the fuse box from the battery for more room.

Figure 6

Remove this bolt and the hydrolic line if you haven't already.

Figure 7

Unbolt the transmission sensor from the transaxle (the formal name for transmission)

Figure 8

There are things that can be removed from the top of the transaxle so if you know what you're doing, go ahead and remove the simple stuff.  Otherwise, consider yourself new to this and you can go through the rest of this artcle and follow the intructions step-by-step.

 

Next (2 of 10)

Brought to you by on Wednesday, July 16, 2003 (UMST)
 

Comments:

Clutch instal
By JB4AZ on Sunday, August 15, 2004 (UMST)

Rad,

Did you have any problems when you were installing the clutch disc and pressure plate on the flywheel.  I'm doing the clutch on a friend's '91 ST 1.6L and am having problems.  When I attempt to align and bolt on the the clutch disc and pressure plate, the pins on the flywheel do not go through the holes on the pressure plate's mounting flange.  It's as if the disc is too thick or (what I believe) the surface on the new pressure plate is closer to the flywheel than the OEM.

The parts stores show 2 kits depending on the build date (before/after 6/00).  I've tried them both and each have the same issue.  After bringing home the second kit I went ahead with bolting it together, but this puts tension on the pressure plate and basically engages the clutch.  So when you bolt up the tranny, there is nothing for the fork and bearing to push against b/c the clutch is already engaged.

After 3+ hours of round trips to the parts stores, I'm giving in and heading to the dealer tomorrow.  I think it must be something with this production model.  One store clerk said it also matter if it was built in Japan or Canada.  Just curious...how did your new clutch disc and pressure plate fit on your flywheel.  Did the pressure plate mounting flanges make contact with the flywheel (so the flywheel pin popped through the PP holes) even before you bolted it on?

Thanks!

Great Site! 

Joe Majewski
JB4AZ@cox.net

 

Reply to this Comment
 

There is only a slight difference between the models of those two building dates
By smbius on Monday, September 27, 2004 (UMST)
There is only a slight difference between the models of those two building dates but either way the pressure plate will bolt on with no problems despite the "thickness" of the clutch you're experiencing. The clutch will always engage irregardless unless you're driving. The fork is meant to disengage the clutch once the tranny is bolted back on. When you bolt the pressure plate just make sure you do not overtorque the bolts. I will be updating this article to put in the correct bolt torque specs.

Reply to this Comment
 

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