DIY Clutch & Flywheel install for Scion tC
 

Warning: These stunts where performed either by professionals or under the supervision of professionals
to ensure the safety of import tuners and motors alike. Accordingly, "TENNEYtheTC" and associates must insist
that no one attempt to recreate or re-enact any of these mods or activites.


Tools:

(I highly suggest printing all of this material up and reviewing it for a few days before attempting this.)
The 2005 - 2006 Scion tC Factory Repair Manual (about $10.00 on ebay from "funkwaffel")
A write up and pics by "rrimportracer" on Scionlife
A write up by "lo bux racer" on YourSciontC.com

A standard mechanics tool set (two sets really help)
19 mm deep well
24 mm deep well
1-1/16" deep well (optional way to refill the tranny fluid)
assortment of 1/2" drive extensions
air compressor and 1/2" air drive wrench
rubber mallet or hammer
mini pry bar
assortment of small and large pliers
measu-funnel (funnel with the hose)
3 quarts new tranny fluid API GL-4
two jacks and jack stands
a friend that has nothing to do for at least 12 hours

1. Let your car sit over night to cool
2. Remove anything out of the trunk before disconnecting the battery. (or suffer the consequences of crawling
through the car )
3. Remove the battery, battery tray, battery carrier, and air intake system
Attachment 21692
Attachment 21693
4. Remove anything bolted to the top of the tranny (this is the back up light switch connector, the wire harnesses,
the main engine ground) I think the main engine ground is under the starter, so you will have to now
Attachment 21694
5. Remove the starter and then the main engine ground
Attachment 21695
6. Remove the clutch release cylinder assembly (tuck it in the front bumper)
Attachment 21696
7. At this point we removed my engine torque dampener (it could bend or be damaged if left on through this job)
Attachment 21697
8. Block the rear wheels and put your baby on jacks
9. (THIS WAY IS THE WAY WE DID IT there are options) Next remove the lower sub-frame assembly and front sway bar
(before you drop it completely put the jack on it so you can lower it down with the jack and slide it out the front of
the car
Attachment 21698
Attachment 21699
10. Remove clutch cables (we found this easier to do from under the car)
11 Remove the tranny drain plug and drain the old "STANK ARSE FLUID" from the tranny (put the plug back after it
drains)
12. Next we poped the driver's side axel out of the tranny (this is where we used the mini pry bar against the part
of the
transmission that sticks out and the groove on the axel) and remove the two bolts on the drive shaft bearing case
(passenger side axel) and pull it out of the way towards the passenger side
Attachment 21700
Attachment 21701
13. Next we hung the axel out of the way (we use wire coat hangers for stuff like this, but rope or bungees will work
also)
14. Next we put a jack on the engine and the other on the transmission
15. Remove all of the tranny bolts
16. Remove the transmission (this requires some prying, shifting, and shimming) lower the tranny using the jack
Attachment 21702
17. Remove the clutch release bearing from the transmission and install the new one (if one came with your clutch kit)
Attachment 21703
18. Remove the clutch and the flywheel (the clutch disc will fall once the clutch cover is removed and the flywheel will fall
once the bolts are removed
Attachment 21704
19. Take a break, smoke one, drink one, whatever just do something else for a few minutes
Attachment 21705
20. Now install your new flywheel and clutch using the alignment tool to keep the clutch disc centered while bolting on the
clutch cover
Attachment 21706
Attachment 21707
Attachment 21708
Attachment 21709
21. Now get the tranny back into position under the car and get a jack under it (jack the tranny up and manhandel that bastard
back on to the engine) this was the hardest part for us, we had to turn the crankshaft pulley to align the crankshaft with the
input shaft spline on the tranny

Now bolt everything back together in the same exact way you took it apart. Refill the transmission with fluid (if you have a 1-1/16"
deep well socket you can remove the back up light sensor and refill from there) or you can refill it from the actual fill plug with the
measu-fill funnel, two and a half quarts only.

Now give yourself permanent blue balls cause you gotta drive easy on this for at least 500 miles.
:tap:

Thank you for the DIY

:clap: aha! finally in scionlife! how bout tech section?

how can I move it to tech?

definatley Tech section

Dont think ill be trying that myself tho, lol

the moderators will move it but they have to see it and decide, i guess we'll just wait

For a beginner/noob/rookie how long would this process take to do, if even possible with having no knowledge of ever replacing clutch/flywheel setup.

^^ I would not advise it to a noob unless an experienced installer is there. Even for someone with experience would take like around 4 hrs or maybe longer depends on how aggressive the work on it. And yeah if you dont get a new flywheel, you might need your stock flywheel resurfaced too which is another trip to a machine shop

I would consider myself and my buddy that helped me "Sophmore/Juniors" and it took a solid 12 hours. Once you get the manuals and study what all needs to be done, it is a silly amount of bolts, there's not much you can do about that. I felt ALOT better about doing it at the beginning of a three day weekend just incase.....

in a rating from 1- 10 and 10 being the hardest what would you give this?

umm awesome

nice.
much props.

Props to TENNEY! Definitely one of the best write-ups I have seen! I am not as mechanically inclined and this is a thorough enough write up for me to know that I will be getting someone to do my clutch/LSD. Thanks Tenney! You probably saved me from ruining my tranny and spending hundreds if not thousands more getting it fixed after I f-ed it up..... GREAT JOB!

awesome diy

12

:rofl: I rate it at a 9 "Pain in the A55" factor :rofl:

hey not on the tech sectioned? might have mine done today

thanks for the writeup! didnt look too bad at all!

ive installed a supercharger, done the front sway bar numerous times... a lot of your steps are included in those two installs. good to see there isnt TOO much more!

just mine done today, its not as easy as it looks like but got it all done in like 5-6 hrs.. im noticing a rub or something hitting while i crank though but nothing after, any clue what the problem could be

This is a good DIY, my clutch just gave out 2 days ago, it had 105, 500 hard miles on it, I was going to try it myself, but with the S/C on the way, I decided to let a friend of mine do it in his shop instead, he is installing a TRD clutch I had sitting around for almost 2 years( :doh: ), I wanted to do a flywheel as well, but I can't afford it right now, I can't even afford the clutch install, this could not have come at a worse time, I have to use a credit card I did not want to use, anyways...sorry for the rant, can't wait to get my car back.