Tools and Materials:
- Jack and jack stands
- Transmission jack or support
- Fluid pump for brake fluid
- Socket wrench set
- Phillips head screwdriver
- Flathead screwdriver
- Pliers
- New clutch kit (including clutch disc, pressure plate, release bearing, and alignment tool)
- Brake fluid
- High-temperature grease
Step-by-step Guide:
1. Preparations:
- Park the Avanza on a level surface, engage the parking brake, and turn off the engine.
- Allow the engine to cool down if it's been running.
2. Raise the Vehicle:
- Place a chock behind one of the rear tires to prevent the car from rolling.
- Jack up the front end of the vehicle using the jack until it's high enough for you to safely crawl underneath.
- Secure the vehicle using jack stands placed under the appropriate points of the chassis.
3. Remove the Transmission:
- Detach the negative terminal of the battery.
- Use a fluid pump to extract any brake fluid from the clutch master cylinder.
- Disconnect the clutch cable or hydraulic line from the transmission.
- Remove any electrical connectors attached to the transmission.
- Disconnect and remove the starter from its location.
- Locate and remove the transmission mount and other mounting bolts/nuts.
- Position a transmission jack or support under the gearbox to hold its weight.
- Remove the gearbox cross member (if applicable).
- Carefully lower the transmission away from the engine using the transmission jack or another suitable method.
- Once lowered, pull the transmission out from under the vehicle.
4. Inspect and Replace Clutch Components:
- Inspect the flywheel for wear or damage. If necessary, have the flywheel resurfaced at a machine shop.
- Attach the alignment tool to the clutch disc to center it properly.
- Carefully position the new clutch disc onto the flywheel.
- Then, install the pressure plate over the clutch disc and secure it with the pressure plate bolts.
- Lubricate the release bearing with high-temperature grease and install it onto the clutch fork.
- Remove the alignment tool.
5. Reinstall the Transmission:
- Carefully raise the transmission into position using the transmission jack or a suitable lift method.
- Reinstall the gearbox mount and other mounting bolts/nuts.
- Securely attach the starter and reconnect any electrical connectors.
- Reinstall the transmission cross member (if applicable).
- Reattach the clutch cable or hydraulic line.
6. Bleed the Clutch Hydraulic System:
- If the vehicle has a hydraulic clutch system, bleed the clutch line using a suitable technique (refer to the vehicle's service manual).
7. Complete the Reassembly:
- Refill the brake fluid reservoir.
- Reconnect the negative terminal of the battery.
- Lower the vehicle using the jack.
- Double-check all connections, bolts, and electrical components.
Note: While this guide provides a brief overview of the steps, the actual process can be complex and may vary depending on the specific Avanza model and year. For safety reasons, it's strongly advised to consult a qualified mechanic or refer to the Toyota Avanza service manual for precise instructions.
