Do it Myself Clutch Repair
DO IT MYSELF CLUTCH TROUBLE REPAIR
Car: Toyota Corolla 1.6LE
SYMPTOMS: Started difficulty in shifting into 1st gear. But as time passes the difficulty of shifting to 1st gear became severe and it eventually impossible to move your stick to 1st gear. Result? Stalled car, but one immediate action just move your car into a safe place and free from towing was to stop the engine then shift into 1st gear then start the engine. Eventually the car will move and you can parked it into a safe location. You must take precaution, light up your emergency light or hazard light, make sure no vehicle before you because starting at first gear will make your car run too fast, put ur hand always at the key, stop engine if there is an obstruction, and use brake and handbrake if necessary. These tips are for emergency purposes only. Never try if you don`t know what i`m talking but none the less it will help avoid costly towing services.
I have brought the car to the a mechanic but unfortunately misdiagnostic happen sometimes even for veteran mechanic. What they did was to change the clutch assembly (release bearing, disk,cover etc). But after replacement, I test it and still experienced same trouble and symptoms. Since my vehicle was stalled near home I decided to repair it myself since I have idea what was the trouble. It was Sunday and a great oppurtunity to learn something since I have no other activity for the day. Also will able to save costly repair and services. The trouble? I suspect that the main causes is either master clutch cylinder or slave/secondaryclutchcylinder/baby master. So I have a little stretching then began my Do It Myself Repair.
First I check the baby master cylinder. I wasn`t able to take shot of my actual repair due to dirt,grease and oil in my hand. I have no assistant during my little Do It Myself. But I have shots after and just make little labeling on it:
To check the inner piston and parts(plunger) for damage of the secondary/baby master cylinder.
Do the following instruction.
1. Remove or loosen boot cover shown above. If there a fluid in it. 100% defective inner parts. Your inner piston/parts need replacement.
2. If there is no leak, no need to check further. Your baby master is in good condition and you have to check main master cylinder instead.
3. If there is leak, replace your inner parts or buy unit assembly same as above.
4. But to save cost of replacing with new one, buy repair kit instead. Either Seiken or FIC brand repair kit will be enough. Banawe or C.M. Recto will be great place to buy this parts.
5. To replace parts, Loosen the bolt #1 and 2. This will unmount the baby master.
6. Remove the inner parts by pumping once of the clutch pedal.
7. That will force the piston and cylinder inner part out of the casing.
8. Replace it with your replacement parts. Replacement parts will have spring and piston.
9. Re install cylinder with already placed replacement parts.
10. And that`s it, you have completed your do it myself baby master repair procedure.
11. Congratulate yourself. You achieve once in a lifetime simple achievement that was not your job.
Check main master clutch cylinder. Refer to location below.
You can not easily remove the master cylinder assembly.
To do this, you have to loosen the brake master/booster assembly simply because you can`t pull it out without moving a little bit the brake assembly.
As shown above, you have to pull it backward. To do this,
Loosen the bolt fixing the brake HVAC/booster to chassis. Loosen until you are able to pull out the clutch assembly.
To pull out master clutch assembly, you have to loosen and remove the 2 fixing bolts holding it under the dashboard. See below pics.
Also loosen the adjustment bolt and fixing bolt # 2 (not shown).
You have to consider also the loosening of all connected copper tubing prior to pull out.
Once you pulled out the master cylinder assembly. It was easy to replace the inner parts or master plunger with replacement parts. Rule is "what you remove you have to replace." Seiken or FIC brand replacement parts will do good. But in my case, i use FIC but there is leak in the connecting rod until now. I have to observe it then will make some action later.
Repair kit parts will be look like this.
Worth P200.00 at masangkay
Here is the exact parts and number of what i bought for the toyota corolla.
1. Put brake (DOT3) fluid in the reservoir.
2. Ask someone to pump the clutch pedal. It should be past.
3. Ask to pump it by flooring it 6 times.
4. Make the 6th pump stroke to make it steady at floor or fully pressed and hold it floored.
5. Open the bleeder bolt to release air and fluid.
6. Repeat procedure until fluid/no air bubbles was clearly coming out of it.
7. Tighten bleeder and fill up full fluid reservoir with DOT 3 brake fluid.Close cap and clean.
7. Congratulate again yourself for a job well done.
Hope this help for anyone who have the same experience as mine.
A wise spend weekday for me.
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