Toyota Aygo service bulletin

8 May 2014  

There are more than 830 part numbers in Blue Print’s clutch kit programme, covering nearly 2,200 Asian and American applications. Clutch cables, hoses, master cylinders and slave cylinders are also provided. Clutch kits are covered by a three-year, unlimited mileage warranty against manufacturing defects. The firm keeps a close eye on vehicle recalls and service bulletins and one part that has been identified to fail prematurely is the clutch on the 1.0 Toyota Aygo, which also fits the Peugeot 107 and Citroen C1. Drivers began to complain about clutch slip and noise, a funny smell and a total failure of the OE clutch at around 40,000 miles. Toyota issued a bulletin saying that all clutch replacements should be conducted using a larger clutch assembly, replacing the original 180mm clutch with a larger 190mm unit, which can be sourced as a kit from Blue Print. A further bulletin from Toyota stated this would not solve the whole problem and that clutch pedal free play must be checked and adjusted at every 9,000 mile service interval as the amount of free play in the pedal reduces, so does the amount of pressure applied by the clutch cover, which speeds up wear.