Sadiq rahman

40341018

Toyota clutch – write up

reg number:lS08XXO

first of all, the customer came in with a concern that the drive was not smooth and did not
accelerate very well. I then asked at what revolutions per minute (rpm) did the concern
occur? The customer then replied at every rpm. From this I know that the root cause of the
concern isn’t the engine. I then asked the customer when was the last time a service or any
work was carried out? To which the customer then said 2000miles ago he had a service.
They also did extra work customers clutch. They replaced the clutch. I then asked the
customer when did the fault occur? The customer then said the issue occurred recently and
has been getting worse every time been driving it .I then asked the customer to show me
the fault while I was in the passenger seat. The customers driving was very rough, adding on
the fault occurred at every gear. From this I knew I had to remove the gear box as the drive
was had trouble get to the wheel front wheels. I then took the customers number down as I
need it for later when the work was finished and if there was any delays in the repair. I wore
my basic ppe which was my steel toe boots and overalls, I also wore rubber gloves to
protect my skin from oils. I then secured the car on the two-post lift and placed the arms
under the car at the correct axle points. I then performed a pre-inspection before carrying
out any work. I then lifted the bonnet and secured it safely. I then made a job card wrote
down the work to be carried out and any addition work to be carried out with permission
from the customer. It had difficulty engaging the clutch and transferring the drive to the
gear box.

I then got the car on the two-post lift and placed the axle hands at the correct axle points
for the car. I then lifted the car and placed a oil pan under the gear box. I then removed the
oil plug using 23mm socket and ½ inch ratchet and left the oil pan under the car for 15
minutes so that all the oil had been drained. I then inspected the oil and it was black and
had tiny shards of metal at the bottom of the oil pan. The cause of the shards are from
where the customer had been driving the car rough. Also, the driving of the customer would
have worn the clutch and may have damaged it lead to difficultly connecting the drive to the
Sadiq rahman
40341018

gear box. I then hand tightened the drain plug. There after I removed the oil pan out of the
way so it wasn’t in the way causing a trip hazard.

I then lowered the car on the two-post lift and loosened the hub nut using a 25mm hub nut
socket and a breaker bar on both sides. I then loosened the tyres using a 19mm wheel brace
on five 19mm bolts. I then lifted the car and removed the front tyres and put the bolts and
tyres of the way in a safe place. There after i removed the safety pin from the steering arm
ball joint using a 0.5mm hole punch and a ball pin hammer. Adding on I then removed the
ball joint by using 17mm socket and ½ inch ratchet on a 17mm bolt. I then got a copper
hammer and popped the ball joint out. I then removed the wishbone to hub nuts using
17mm socket and ½ inch ratchet on three bolts on the wishbone on both sides and
disconnected the wishbone from the hub. I then lifted the car up on the two-post lift. using
a drive shaft fork and a copper hammer I removed the drive shafts from the gear box. I then
placed the drive shafts out of the way in a safe place. I then removed the battery followed
by the casing and base using a Philips screw driver on 3 screws. I then disconnected the gear
shift lever by removing two retaining clip. I then removed the metal wires out of the way. I
then removed the speed sensor from the gear box. There after I then disconnected the
clutch cable from the gear box housing by removing a retaining clip. I then removed the
clutch fluid pipe from the gear box using a 10mm spanner. Next i then removed the salve
cylinder using a 10mm socket on two 10mm bolts. I then removed the top engine mount by
removing three e16 bolts. I then installed a engine mount on the top of the car on engine
bay and readjusted the engine mount it fitted on top of the engine bay. I then made sure
the engine mount was secure. I then adjusted the engine bay and installed a chain on the
engine brace mount, through the engine top mount for the engine brace. I then adjusted
the engine mount so that the engine mount took the weight of the engine. I then removed
the top offside engine mount using a e16 socket and ½ inch ratchet on 3 bolts. I then placed
the bolts in a box and taped and marked which bolts was for which component. I then
raised the car on the two post lift. And removed the bottom engine mount using 21mm
socket and ½ inch ratchet on a 23mm bolt. I then removed the engine mount behind gear
box using a 19mm socket and ½ inch ratchet. There after I put a transmission jack under the
gear box. I then started to remove the bell housing bolts using 15mm socket and ½ inch
ratchet on eight 15mm bolts. I got someone to give me hand in manoeuvring the gear box
Sadiq rahman
40341018

out from under the car. First I wobbled the gear box side to side and disconnected the drive
shaft from the engine. I then placed the gear box on the floor. There I removed the clutch by
removing sixteen 8mm bolts using a 8mm socket and ¼ inch ratchet.

I then checked the condition of the clutch and realised the clutch had been wearing very
badly and had a spring broken causing the drive to be rough.

Refitting

Using the vehicles make model, year and registration number ordered a clutch and
transmission fluid as well as a salve cylinder as it had bad ware and a litre of dot 4. After
receiving the parts i installed the new clutch and pressure plate using a clutch alignment
tool in the engine. I then hand tighten sixteen bolts 8mm bolts in a cress cross pattern to
install the clutch and pressure plate to the engine dead straight. There after I tighten the
rest of the 8mm bolts to 15nm also in a cress cross pattern using a ¼ inch torque wrench
and an 8mm bolt. I then got someone to help me put the gear box back in the engine bay by
lifting the gear box up into the engine bay. And wobbled the gear box to connect the drive
shaft to the engine. I then hand tighten two bolts one at the top of the gear box and one at
the bottom. I then got a transmission jack and placed it under the gear box. And hand
tightened the other six 15mm bolts into the gear box to secure it in place. I then re
connected the bottom engine mount using a 21mm socket and ½ ratchet and the mount
behind the gearbox using a 19mm socket and ½ inch ratchet. And torqued the bolts down to
60nm. I then got a torque wrench and tightened eight 15mm bolts down to 60nm.following
this step I removed the transmission jack and put it out of the way. There after I removed
the fill plug using a 23mm socket and ratchet and filled the gearbox up with transmission
fluid, I then tighten the fill plug. I then installed the new salve cylinder using a 10mm
spanner on two 10mm bolts. There after I reconnected the gear shift lever by connecting
the joints and two retaining clip back in place. I then reconnected the speed sensor.
Followed by the clutch cable by installing a retaining clip. I then reconnected the clutch fluid
pipe to the bell housing using a 10mm spanner. I then reconnected the drive shafts in the
gear box and reconnected the drive shafts to the hub. I then reconnected the wishbone to
the hub by tightening 3 17mm bolts and torqued the bolts down to 60nm. I then
reconnected the ball joint on both sides by tightening two 17mm bolts and torqued them
down to 35nm and installed a new safety pin. I then removed the fill plug using a 23mm
Sadiq rahman
40341018

socket and allowed the excess transmission fluid to leak out into the oil pan. Once the
transmission fluid stop leaking I stalled the fill plug using a 23mm socket and ratchet I the
torqued the bolt down to 15nm.i then torqued the drain plug to 15nm.

I then refitted the wheels and tightened five 19mm bolts on both sides. Next I tightened the
23mm hub nuts. Then I lowered the car on the two-post lift and torqued the wheel nuts to
110nm and torqued the hub nuts to 213nm using a torque wrench. I then installed the top
engine mount by using a e16 and a ½ inch ratchet on three e16 bolts and then I torqued the
bolts down to 60nm. I then installed the battery base using a screw driver on 3 bolts. I then
installed the battery and casing. And put the positive on first followed by the negative. I
then filled up the dot 4 reservoir to max as it was below the minimum. I then removed the
car off the two-post lift and performed a road test and try to make the fault occur. However,
the fault was fixed (from the root cause the clutch) and the car was running smoothly in all
gears. I then rang the customer to pick up his car and any invoices.

Adding on the clutch wore out and was ineffective due to the driver as he would operate the
vehicles clutch roughly causing the drive to be rough. The cause of this fault was driver error
as the spring inside of the clutch wore down and got lose before coming out and not
allowing the clutch to engage smoothly.