I'm new on this forum, I figured if I'm going to start a thread on my newly acquired 1993 Toyota Corolla Levin AE101. (At least, that's the code for 'em here in JDM markets, I see other people using that same code for the 4dr sedan version with the 4AFE). Then Club4AG seemed like the best community to settle down!
But I digress. I'm simply just looking for a place to put down my thoughts, log my progress, tell tales of my hits and misses and get some feedback from veterans in the 4AGE community. So mods, If I'm posting this thread in the wrong sub-forum or if this isn't the sort of thing you do at Club4AG, then my all means - just set me straight
So to Start off - here are the base specs of my car that I found on the net.... good to just keep it for reference https://www.carfolio.com/specifications/models/car/?car=263010.
It's a 1993 model, bought it with around 180,000+ KM on the clock. Bone stock 4-AGE 20V Silvertop with 5 spd C52 gearbox (Non-LSD). Got the dual exhaust which gives a nice sporty note. I'm dubbing this machine "Di Analys" - and if you're scratching you're head don't worry That's just our Jamaican dialect for saying "The Analyst". I figured instead of giving it the usual pet name, I'd let this car signify a milestone in my life - Got a new job as a Business Analyst (BA) pretty much the same time I bought this car. I'm stepping up from a 1996 Suzuki Swift 3cyl - so you can imagine the performance difference is night and day for me.
But enough of the wordy stuff. I like to tell my stories with pics. So my first tale will be about my firs major repair to the car.... And that was Changing the clutch.
Bout 2 weeks ago I got a little excited and tried to launch to make the gap in Traffic. Boyyyyyy was that ever the last I'd be doing that. HORRID GRIND trying to get into 2nd - clutch pedal sank to the floor - didn't want to come back up. I thought $#!@ - this is the day I screw up my pride and joy. Lo and Behold, I was able to get it moving again but the clutch went from streetable grab all the way down to slipping in 3rd gear. That was Monday - By the end of the week it was slipping so bad that I couldn't even get it past 3K RPM in 1st gear! Talk about a nightmare.
Now up to this point, I didn't have a dedicated mechanic. The location of my new job meant I couldn't just go round the block to my usual mech - So I needed to try something new! Tried searching the interwebs for mobile mechanics since I'd need the someone that can come to my location when I'm in a pinch. Finally boiled down to mechanics that advertised their work like this Or Like This....
I think I know which of the two put some effort into their work. So I messaged Travis The Mobile Mechanic on facebook https://www.facebook.com/travisthemobilemechanic/ and we got to talking about what kind of jobs he's done and to take a first look at Di Analys initially scheduling him for August 11
Fast forward to slipping clutch week and BOOYYYYY did I have a trial by fire ready for Travis the Mobile Mechanic He actually came from the shop >>> to my home >>>> to help get the car back to the shop at Rodgers Tyre & Service Center in Portmore, right around here http://bit.do/euBmo
And so our journey begins
Some way, some how. We managed to drive it on the slipping clutch about 21KM to the shop. Here's your first look at the car about to go on the lift
Doubt the car even cooled off properly before Travis started on the case - unbolting bits and pieces from the top before we jacked it up
And it's up! I swear it was like 30 mins between the time I pulled up, to the time the car got lifted - almost like they change clutches for a living
Impact wrench makes quick work of the plastic undertrays and many other bolts for the various supports under the car. When all was said and done, we found some wet spots under the car - explains why I gotta top up with 10W40 a couple times and top up Power Steering Fluid. But right now that is the least of my concerns
And there it is, Gearbox is off. Old Pressure plate exposed and ready to go
There's the culprit. Whatever I did with that launch COMPLETELY DISINTEGRATED one side of the clutch disc. I was holding on by the rivets for God's sake. The bellhousing was completely filthy - shredded organic material and oil everywhere.
First thing's first, we realized the rear crankcase seal was leaking into the bellhousing. By some stroke of luck, the nearby auto parts shop had one. So we replaced it straight away. The old one was as stiff as a piece of styrofoam!
Blasted the bellhousing innards with a pressure washer to get all the gunk out. And then set it on its side to drain oil the old gear oil.
So here's the part where I show you all the new shiny bits that I'm gonna replace.
- Most important is the clutch kit. Its an Ebay Stage 3 Clutch Kit https://ebay.to/2KH2zCv Comes complete with Stage 3 Clutch, Pressure Plate, 200MM Lightweight Chromoly 10lb Flywheel and Throw Out Bearing.
- Next up is the ARP Flywheel Bolts - also bought it off Ebay https://ebay.to/2MyCkjp Comes with 8 bolts and the assembly lube. They can take 58 ftlbs compared to stock 54 ftlbs AND they're re-usable.
- Also needed about 4 quarts of 75W90 Gear Oil. Most of the Auto Parts stores had 80W90 and the only 75W90 was Amsoil - really Expensive $#!@ Dangit! had to bite the bullet and buy 4 quarts of the Amsoil Synthetic. looks like this http://bit.do/eubEj
I bought a small tube of thread locker but mech opted for the Assembly Lube instead. ARP bolts lubed up. Bolted in the new 4.7KG (10lb) flywheel down to 58 ftlbs. For reference, here's a neat site comparing the 20V flywheel weights http://www.my-acoustic.com/Car/weight_issues/compare_20v_flywheel_weight/compare_20v_flywheels_weight.htm. Then bolted in the Stage 3, 6-puck clutch and blue pressure plate. Sorry I didn't take more pics at this point, as you can see - it was starting to get late.
A fair bit of elbow grease and some helping hands Travis got the gearbox back in place and wasted no time putting together all the pieces. It was like 4:30PM when we reached the shop - And by the time it was all done it was about 9:30PM. Dunno how many mechs in the states stay in the shop till those times, but I'm glad I had Travis in my corner. Damn good labour price too if I may say so myself.
I'm writing this about 1 week later from the install date and all I can say is, don't let people on the internet scare you from lightweight flywheels and Stage 3 clutch setups. The thing is entirely streetable, no chattering, you can still slip the clutch, and the RPM movement up or down isn't as dramatic as some make it sound. I'm about 100KM into my 1000KM break-in period and the level of rebound coming from the pressure plate is the only thing to get used to.
Phew! That took longer than I thought.