Clutch Install Guide | FRS BRZ 86

Introduction

This tutorial provides a comprehensive guide to replacing the clutch in your FRS, BRZ, or 86. Whether your stock clutch is worn out or you're upgrading for increased power, this step-by-step guide will walk you through the installation process using an XClutch sprung organic clutch kit and other essential components.

Step 1: Prepare the Workspace

• Disconnect the battery and remove it for better access.
• Gather necessary tools: 10mm and 14mm sockets, ratchet, pry bars, transmission jack (or an alternative), and a drip tray for fluids.

Step 2: Remove the Slave Cylinder

• Locate the slave cylinder behind the intake manifold.
• Remove the two 14mm bolts and set the cylinder aside.

Step 3: Disconnect Wiring and Exhaust Components

• Disconnect the ground wire (12mm bolt) next to the slave cylinder.
• Disconnect the starter by removing the black connector and the 12mm nut under the rubber cover.
• Remove the under panels and the middle section of the exhaust (front pipe and mid-pipe).

Step 4: Drain the Transmission

• Locate the fill and drain plugs on the driver's side, using a 10mm hex key.
• Crack open the fill plug first, then drain the transmission into a pan.

Step 5: Remove the Driveshaft

• Mark the driveshaft orientation with a paint marker.
• Remove the four 14mm bolts securing the driveshaft to the rear differential.
• Remove the two additional bolts holding the driveshaft in place towards the middle of the car.

Step 6: Remove the Transmission

• Support the engine with a block of wood under the oil pan.
• Remove the transmission mount bolts and the front pipe bracket.
• Disconnect the shifter linkage: pull the rubber boot down, remove the cotter pin, and the black washer.
• Remove the two pins on the shifter carriage.
• Remove the remaining bell housing bolts (total of eight).

Step 7: Replace the Clutch Components

• With the transmission removed, take off the stock clutch, pressure plate, and flywheel.
• Clean the flywheel with brake cleaner.
• Install the new flywheel, ensuring the pilot bearing is pressed in, and torque the bolts in a star pattern to 35 ft-lbs, then to 63 ft-lbs.

Step 8: Install the New Clutch

• Place the clutch disc onto the flywheel using the alignment tool.
• Install the pressure plate and torque its bolts to 26 ft-lbs in a star pattern.

Step 9: Install New Clutch Fork and Pivot Point

• Remove the old clutch fork and pivot ball using a 19mm socket.
• Grease the pivot point and the contact points on the clutch fork and throwout bearing.
• Install the new pivot ball and torque it to 12 ft-lbs.
• Reassemble the clutch fork with the new components and install it in place.

Step 10: Reinstall the Transmission

• Align the transmission with the engine, ensuring the splines are properly seated.
• Reinstall the bell housing bolts and torque them to 37 ft-lbs using blue Loctite.

Step 11: Reassemble Components

• Reinstall the transmission mount, shifter linkage, and driveshaft.
• Torque the driveshaft bolts to 57 ft-lbs and the center support to 35 ft-lbs, using blue Loctite.

Step 12: Refill Transmission with Fluid

• Refill the transmission through the fill plug with approximately 2.2 quarts of Motul Gear 300.
• Reinstall the fill plug and torque it to 27 ft-lbs.

Conclusion

Congratulations on replacing your clutch! Double-check all connections and ensure everything is torqued to spec. Follow the manufacturer's break-in procedure for your new clutch. If you encounter issues, consider seeking help from a friend with experience. Enjoy your upgraded performance on the track!