Aygo Clutch Modification

[Bob Warriner]

Hi everyone, my name is Bob, and I'm new to this forum.

I have owned an Aygo Sport since January 2006, never had any significant problems with it, so very pleased with the car.

Last Saturday someone ran into the back of me, I was stationary at the time waiting to enter a roundabout, quite a crash, I expected to get out an see a completely wrecked rear end, but to my surprise the crumple zone had taken most of the force and so there wasn't much to see, the plastic bumper had sprung back to it's original position, with just a couple of punctures where the plastic had hit some of the main chassis, I was very impressed by that, and no damage there either.

The driver that hit me apologised and said he had taken his eyes off the road for a split second, and took full responsibility for the accident, I asked him if he wanted to go through an insurance claim or would he be prepared to pay for the work privately, he agreed to pay privately as long as the estimate wasn't too high, so far so good.

Now to the point of this post: I took little Aygo into my local Mr T and asked for an estimate, they were very good as usual, had the car on a ramp in a matter of minutes, while I poured myself a free coffee.

After a little while, an engineer came to see me to explain the damage, and to also state that they had a recent memo from Toyota saying that Aygos needed a clutch modification, and this would be done under warranty at the same time as the repairs, IS THAT RIGHT? I don't see any reference to a clutch mod in any forums I have visited.

Has anyone heard of a directive from Toyota about a under warranty clutch modification?

Rgds Bob.

[weevicky]

Yes I had the same problem with my aygo. The clutch on some of the Aygos are set too high; so basically they just need to move the clutch out a bit and shouldnt take 10 mins.

Doesnt need to be mentioned to the insurance becasue its not really a modification; its just fixing it to what it really should be.

[Bob Warriner]

Yes I had the same problem with my aygo. The clutch on some of the Aygos are set too high; so basically they just need to move the clutch out a bit and shouldnt take 10 mins.

Doesnt need to be mentioned to the insurance becasue its not really a modification; its just fixing it to what it really should be.

Thanks for that, I was told that the gearbox has to be dropped down for the adjustment to be made, a little more that 10 minutes methinks, but Parts-King will know.

Rgds Bob.

[Parts-King]

There is a special service bulletin out on it, nothing to worry about, it is FREE!

Kingo

[crisskro]

First time I hear about the bulletin. Got any more info on that?

[BadBoyVTEC]

Should we all inundate toyota by all turning up there to get it done immediately or just wait for our service?

[Smithy07]

I've always said that the clutch is too high but put it down to learning in a different car

Have the day off on Friday ... may pop into mr T and make some enquires as i need to book the 3rd Service / MOT in anyway .

It'll seem weird having a lower clutch lol

[weevicky]

It was very hard. It was a private garage that told me that it was set too high and to tell toyota. Take your aygo and get it sorted before the warranty is out; it could wear down your clutch quicker if it is still too high.

[Smithy07]

It was very hard. It was a private garage that told me that it was set too high and to tell toyota. Take your aygo and get it sorted before the warranty is out; it could wear down your clutch quicker if it is still too high.

Yea , my warranty is up in September so was thinking of getting it all out of the way before then :)

When i was in MR Ts last year getting the bumper fixed , i told the garage it feels too high and they said that it's normal

[Bob Warriner]

I've always said that the clutch is too high but put it down to learning in a different car

Have the day off on Friday ... may pop into mr T and make some enquires as i need to book the 3rd Service / MOT in anyway .

It'll seem weird having a lower clutch lol

Yes, I'm wondering about that, I must say I thought the same as you when I first picked up the car from new...same model as yours actually, but like you I just assumed that was the way the clutch was supposed to be, never gave it another thought, just got used to it.

Everyone that read my original post can rest assured that the crumple zones on an Aygo really do work, no wonder the car got 4 stars for safety.

A bit on the expensive side to repair though....but not my problem :)

Rgds Bob.

[SJandMR2]

Sorry to read about your car, but thanks for testing the crumple zone for us

Interesting re clutch, Aygos my first car so have got used to it as norm, have found it difficult adjusting to other cars cluthes tho, might mention this at my service at the weekend

Welcome to the Club :D

SJx

[BadBoyVTEC]

The new clutch in my Aygo makes a horrible skueaking noise from the clutch spring. I was gonna put up with it but hearing this I think I will tell them to sort it.

[crisskro]

I thought the triplets got only 4 stars Euro NCAP.

[BadBoyVTEC]

they did

[Bob Warriner]

they did

Quite right, sorry, my mistake, just edited.

Rgds Bob.

[peugeot107?]

Presume the clutch mod does not apply to the MMT/2tronic.

[miss_d_bus]

Presume the clutch mod does not apply to the MMT/2tronic.

Yes I'd like to know that too (just to be 100% sure!)

[judebr]

I took my Aygo in for it's 3rd service and 1st MOT at the weekend.

I mentioned that the clutch had been making an intermittant groan when pulling away (especially on an incline) for the last few months and also mentioned about the service bulletin modification.

They could find no record of the service bulletin modification but I am getting a new clutch!

Thankfully I still had 2 days of my warranty left!!

[Bob Warriner]

I took my Aygo in for it's 3rd service and 1st MOT at the weekend.

I mentioned that the clutch had been making an intermittant groan when pulling away (especially on an incline) for the last few months and also mentioned about the service bulletin modification.

They could find no record of the service bulletin modification but I am getting a new clutch!

Thankfully I still had 2 days of my warranty left!!

Wow, that's a surprise, are they Toyota main dealers? if so, they have missed the bulletin somehow :(

Just make sure that they set the new clutch at the correct height, or you'll get premature wear again.

Rgds Bob.

[judebr]

Wow, that's a surprise, are they Toyota main dealers? if so, they have missed the bulletin somehow :(

Just make sure that they set the new clutch at the correct height, or you'll get premature wear again.

Rgds Bob.

Yes, it was a main dealer. He said he couldn't find an record of it at all. If anyone has some kind of reference number for the bulletin I'd be grateful.

[Parts-King]

Tell your dealer to view TOTTS, it is a bulletin refering to clutch height and wear rate on Aygo clutches.

Kingo

[JustinH]

Took mine down to the local dealer this afternoon. They adjusted (I think I remember this correctly) the bite point via the cable, and the pedal stop. To be honest in the short trip home from there the bite point still feels like it's around about the same sorta place (close towards to top end of the pedals travel), but the pedal definitely has less travel and feels tauter and more controllable. Will see if I notice more difference during the drive to work in the morning.

[ikduncan]

car went in for a service my toyota delaer is pleading ignorance re: clutch

any more details exact link/bulletin date / reference number

exactly what the bulletin says?

[dreaddan]

Did you find out the details of the bulliton?

[moonstone mart]

Did you find out the details of the bulliton?

The bulletin was to check the free play in the clutch pedal/clutch cable and adjust if necesary to 23mm.

Obviously if customer fells pedal is too high that can be adjusted on the stop too.

Mart.