Clutch Install Instructions

[wakil]

Hey guys, been looking through and had no luck but if someone's found the topic I'm after please shoot me a link!

Clutch is all but dead in my lux, (08/2008 diesel) and I'm pulling it to bits on Friday to install a new one.

I would really like a blow-by-blow right up on how it's done, what to look for, flywheel details, clutch diameters etc. a clutch bible if you like.

So can anyone help? I'll post below the "helpful" information I've gathered so far. Feel free to correct me.

Cheers

Will

[wakil]

I've been told that pre 08/2008 models have a 260mm clutch with a dual mass flywheel that cannot be machined. There was comment made that as mine is 08/2008 that there's a 50-50 chance of me having the solid mass (machinable) or dual-mass (non-machinable). Apparently the clutch for the single mass flywheel is 275mm. That was from autobarns clutch suppliers.

However toyotas talented service team confidently advised me that all hiluxs have dual mass, which I do not believe at all, but again, if someone knows this to be true let me know.

At the moment I have picked up a 4terrain clutch, 275mm, without a flywheel in hope that I don't have the dual mass flywheel. If I do though, I'm boned

[buffo69]

I question the talent of your Toyota advice, I had to just confirm with with mate from high school who is a service foreman and he confirmed with his offsider who has worked there for many more years than him, that the later stuff does not have a dual mass flywheel, and they are also pretty sure the early stuff doesn't either.

[boxhead55]

Wow this has really done the traps. HILUX DO NOT HAVE A DUEL MASS FLYWHEEL!

[Blackie2008]

Be careful because I have a August 2008 Hilux and I'm pretty sure Brendon at Ultimate Suspension found that the Prado's have the 275mm clutch we have a 270mm (that has a different step in it so not compatible with the Prado's unit) and pre ours is the 260mm. Make sure they're not ordering you the wrong bit. Maybe get a second opinion just to be sure, could save you some trouble.

[andy666]

Well one tip I can give you is to remove the transfer case from the gearbox. Then remove the gearbox. This makes things lighter and easier to handle. It also give you more room, so you don't have to tilt and manoeuvre the gearbox as much to remove.

[boxhead55]

Yes blackiee you are right there is a different clutch after that

[wakil]

I question the talent of your Toyota advice, I had to just confirm with with mate from high school who is a service foreman and he confirmed with his offsider who has worked there for many more years than him, that the later stuff does not have a dual mass flywheel, and they are also pretty sure the early stuff doesn't either.

Yeah I was pretty concerned with their expertise, couldn't believe that the guy was from the service department

Be careful because I have a August 2008 Hilux and I'm pretty sure Brendon at Ultimate Suspension found that the Prado's have the 275mm clutch we have a 270mm (that has a different step in it so not compatible with the Prado's unit) and pre ours is the 260mm. Make sure they're not ordering you the wrong bit. Maybe get a second opinion just to be sure, could save you some trouble.

So am I right in saying that I should have a 270mm clutch not a 275? Can anyone else confirm this, cause it's kind of a biggy!
Is that what you thought boxhead?

Well one tip I can give you is to remove the transfer case from the gearbox. Then remove the gearbox. This makes things lighter and easier to handle. It also give you more room, so you don't have to tilt and manoeuvre the gearbox as much to remove.

That's a good idea mate, should make things a bit more accessible

Wow this has really done the traps. HILUX DO NOT HAVE A DUEL MASS FLYWHEEL!

mate if that's for real I am never taking my ute within a 50km radius of a Toyota joint ever again haha! Could they be that wrong?!

[boxhead55]

Mate the difference is after 8.2008
Is

It has a 55 mm friction surface
The old flywheel is

It has a 50mm friction surface

Best thing is to order the clutch by year of manufacture or vin number.

[boxhead55]

And as you can see the pic of the 2013 flywheel it is NOT A DUEL MAS FLYWHEEL!

[Skog07]

Thanks boxhead, you certainly have a wealth of knowledge and thankyou for sharing it with this forum.
Cheers
Mark

[StevenS]

Wouldn't take Toyota Service fellas word on anything, they aren't the mechanics or technicians afterall.

Especially after my local mob refused to believe the D4D had glowplugs. Their reasoning?
"It's a common rail which means they don't need them"

[wakil]

Mate the difference is after 8.2008

Best thing is to order the clutch by year of manufacture or vin number.

Hey mate, thanks, if i can just pick ya brain a little more, ive bought a clutch based on year and VIN and its a 275mm clutch does that sound right or is the consensus that its either 260 or 270mm?

Andddd do you know the torque requirements for flywheel bolts if it is indeed a single mass? or where i can get these details?

Much appreciated mate!

[fnqtech]

I put a 4Terrain in my 2007 earlier this year. 260mm and definitely not dual mass flywheel. Didn't bother removing the transfer case and did it on my back on the driveway with a trolley jack and a bottle jack to take the twist of the transfer case. Pretty easy job although a bit fiddly getting it back in as its quite a tight fit

[wakil]

Ok got the clutch in today, the 275mm 4terrain clutch was spot on! Single mass flywheel.

Flywheel had a fair few hot spots but apparently they didn't take much to lathe out. And clutch plate was worn but not quite down to the bolts, still a bit of pad, like I said though it was definitely slipping.

Went to start the ute up, RATTLE RATTLE BANG RATTLE RATTLE. White smoke. The injectors have finally all but died, ute still running but the start up was pretty severe

[Blackie2008]

I just went and measured the 4Terrain clutch plate that I've got here ready to go and yeah, it 275mm across. I'm officially confused again with how it compares to the Prado unit but who cares, as long as this one works better than the standard one!
Maybe the 5mm difference was to do with a step or something in the Prado's flywheel... Stupid memory.

[wakil]

Haha as long as it fits and it works who cares! Haha I'm so relieved, I was
Pretty concerned with all the conflicting reports haha good luck with it!

[Skog07]

Here are some pics of my 2007 original clutch. It was replaced at 151000kms. It still had about 1/2mm on the friction material until it hit the rivets on both sides. This clutch copped a fair amount of use, it frequently towed around a 2.4 tonne plant trailer with a 1600kg excavator on the back with buckets, hammer and a gull wing canopy full of tools. a fair amount of mechanical sympathy was needed to get such a long life out of it, this included doing low range 1st gear starts at traffic lights driving it a straight line only up until low 2nd, then a flick up to 2H first gear and pretty much driving all low speed up to 50kph 4wding in low range.
Its a 2007 model so it has a 260mm dia friction area.
See pics.

Rear main seal, throw out bearing, thrust bearing and pivot point were also changed out whilst the transmission was split.

Back of clutch assembly

The two halfs side by side.

and the assembled unit.

I do remember a member on here called Dluxv6, had a lot of troubles with his clutch. He managed to fit the larger diameter Prado flywheel onto an older model (260mm) engine with a heavier duty clutch. I think he got some good results from it. But he needed to purchase a new flywheel.

[Blackie2008]

That's where it gets proper expensive! It might have been before there was a HD option for the later model cars.

[wakil]

For the record skog, and to help future people doing this, was your 07 a dual or single mass flywheel? And it's definitely the flywheel that's the price killer. I was lucky to have an uncle and a cousin to help me fit it for low cost too. Fitting is expensive