2012 Hilux clutch fails at 50000km

[mrcranky]

Does me, but I'd like to know what's going on

[ATompkins]

my 09 has 120k on the original clutch. works fine. when off road I always use low range same as low speed uphill starts towing a loaded car trailer. ability to use low range 2wd comes in handy.

Yes, this is what I have decided to try. Rather than 4WD high range use the low range rather. Under the circumstance I should not have had to but will try this for interest sake to see if there is a difference.

[ATompkins]

Hi.
I have a 2013 Hilux. 3.0 D-4D SR purchased in Jan 2014. I hired a similar 2012 model in Namibia and drove 6000km through some rugged country and was sold on Hilux. So on my return to Australia bought one. However at about 3000km I took it to Bribie Island and in some very mild sand driving the clutch started to overheat badly. I have been there many times in other vehicle types and never had issues except in the Hilux. I don't tow anything and this problem occurs even when lightly loaded but always when in 4WD.

Toyota dealer was very good and replaced it without an issue. However the next trip with the new clutch it got hot again when doing very little work. I have come to the conclusion these vehicles have a seriously under rated clutch and Toyota don't seem to openly admit it. I guess most of the 4WD utes of this type don't end up in 4WD drive conditions and may be fine for on road work but they are definitely not designed for off road conditions. I just wish the salesman had pointed this out and then I would have ordered an auto instead. Otherwise it is a great vehicle and enjoy it but this is a serious fault.

Surely Toyota should fit a heavy duty clutch version under warranty if this is an issue? If I did fit a heavy duty version would it affect the warranty?

Any recommendations on the course of action and what clutch should be fitted?

The dealer has been very good but I guess they can only try their best to back up what Toyota have designed.

Toyota will not fit a heavy duty clutch under warranty, been there done that with my previous hilux. I had three genuine clutch replacements within 100,000km, sold it just out of warranty and bought an auto.

Go with a warranty repair, chances are you'll need another clutch close to 100,000km anyway so fit a heavy duty one then. Could be something else going on and fitting an aftermarket clutch will void your warranty, what happens if it turns out to be something else causing the issue? I'd be taking it to another dealership with the hope they are more cluey than the last mob!

Thanks for the advice. I will be doing basically that. The dealer has been good about it and I do think its a great vehicle so will just keep reporting the issue if it persists in the warranty period.
When they changed the clutch at 3000km's the report was that the springs in the pressure plate were not strong enough and due to that it was slipping. Fair enough. So they replaced the clutch parts and also skimmed the flywheel.
I don't mind if manufacturers have issues as its not a perfect world but as long as they help the dealers uphold their side its fine. So far for me they have.
Some vehicles seem to be ok and some not but I guess that could be a batch issue or perhaps a point in time when something changed.
For my vehicle I do know something is not right as it should never overheat under the circumstances I used it in. I always go with my mate and his old Triton is fine and so was my old Ford Courier in the same conditions.
Logically I can only see the fault being in the following 3 categories:
1) An adjustment being wrong.
2) Spring pressure being too light on pressure plate
3) Material of the clutch plate itself being inferior or bad quality

Not being an expert I am not sure if 1) is a possibility? But 2 and 3 are surely possible.

I guess it's also quite difficult for the dealers to test the clutches in their road tests and try simulate the 4WD situations.

Thanks again for the input and I will hopefully resolve it.

[Richolux150]

I had a 2007 and went every where abd did not replace the clutch. My new 2013 is just the same not a problem as yet now over 60 000 km and still fine. I tow I 4x4 and I have recovered with it. No problems.

yeah same........no problems with my 2012......had a clutch go in a Rodeo after 170 000 k but then she was making some funny sounds for a few weeks before

[Richolux150]

I had a 2007 and went every where abd did not replace the clutch. My new 2013 is just the same not a problem as yet now over 60 000 km and still fine. I tow I 4x4 and I have recovered with it. No problems.

yeah same........no problems with my 2012......had a clutch go in a Rodeo after 170 000 k but then she was making some funny sounds for a few weeks before

Yep spoke too soon....just had 60 000 klm service (at 57 000) on my 2012 SR.....service report says clutch is slipping and quoted $1500 ish to replace....not too sure if this may be over servicing because I didn't really notice any problems
I just asked for them to check the clutch.....they said they can pull it out and see if it is wear and tear or if it is a manufacturing issue. Point is I don't trust the dealership for an honest opinion, as they say it's not a common problem.....it's just like putting the fat kid in charge of the candy store......any advise on how to handle this one....

[ATompkins]

Yep spoke too soon....just had 60 000 klm service (at 57 000) on my 2012 SR.....service report says clutch is slipping and quoted $1500 ish to replace....not too sure if this may be over servicing because I didn't really notice any problems
I just asked for them to check the clutch.....they said they can pull it out and see if it is wear and tear or if it is a manufacturing issue. Point is I don't trust the dealership for an honest opinion, as they say it's not a common problem.....it's just like putting the fat kid in charge of the candy store......any advise on how to handle this one....

There definitely is a problem. Mine failing at a few thousand km's and the new one not right again. No towing and very minor work and it overheats. Wear and tear at 57000km???? It really should last more than that!

[dino12]

what kind of revs are you blokes driving at in the vehicles blowing these clutches. the Toyota hilux has huge torque at very low revs, which means it will pull very hard at low revs in high gears loading up the clutch and gearbox. if you drive in a low gear that causes the engine to rev higher, say 2500 revs, it takes the load off the driveline and clutch. in really heavy offroad conditions you could even drive in a gear that gives closer to 3000rpm, but that's only for pretty heavy conditions. but using a higher revving gear sure takes the load off the clutch. not saying you're driving in a gear that's too high, you're probably experienced offroaders, just offering this as a possibility.

cheers.

[Richolux150]

Never done any real heavy towing......a few short trips up Main and Flinders Beach at Straddie with the camper trailer and a couple of trips to Fraser with a 14 ft tinny....but in the sand momentum is your friend and I've been beach driving for forty years (I did start young)......no funny smells....no funny sounds....
no towing giant caravans or boats up stupid hills....I've put this vehicle through far less torture than my previous vehicles......and no I don't put around in a higher gear than necessary....as soon as you put some accessories (only 31" tyres) on your vehicle they assume you drive it like those idiots on 4wd inaction....surely there is a fault they not keen to admit.....

[gsh1po]

Toyota Australia (I wrote to the CEO) have investigated my complaint and rejected the warranty. I am in consultation with RACQ and intend to get them to go to QCAT to get me a result. I have never abused my vehicle and they just need to realise that the composition of their clutch plates is simply not up to a bit of serious hard work. Since I have had the new clutch, I have suspected that it is slipping when doing a little bit of hard work. Once I get a result, I intend to have an Exedy clutch fitted as I don't trust the OE one and I want to tow a camper trailer around Oz for a couple of years.

[Richolux150]

Yep I'll try the RACQ approach as well........QCAT is probably the big stick they need though...

[Richolux150]

bop

[piddo80]

My 2006 HAS LASTED 168,000 - however its been needing replacement for a while. It certainly wasnt buggered under warranty. Im replacing with a 4 Trerrain HD clutch.

From what I understand the clutch was upgraded in the 08 model to a larger flywheel

[knight]

MIne's 2012 and clocked over 90,000 a few weeks ago. It gets hammered towing the camper, boat, driving on the beach, plenty of 4wding and getting on the brake for skids every now and again and its still going strong. Doesn't slip or anything out of the ordinary.

Really seems like its just a random luck or the draw

[mauricem]

2005 D4D, replaced original clutch at in 2012 at 120,000k with Exedy HD. No towing, no hard off road but daily 4wd usage.

Not impressed with new clutch, feels rough and burns very easily. Would hate to have to use it as a recovery vehicle.

[Richolux150]

Good result with Toyota dealer.......seems slipping was caused by a finger being out of align ......
clutch had a shudder or something like that.........so booked in for a replacement next week...........
service manager was very helpful in the end

[Dewbs]

What do you guys suggest as the best heavy duty clutch upgrade? Just purchased a 14 foot jayco camper and we will be towing it around a fair bit, plus we also do some mild off road stuff, and at this stage the clutch was burning just reversing the camper up our driveway.

[Torsion]

I think your pretty lucky to be honest, to get 50k out of it. Id take that and be happy, its not luck of the draw, standard Toyo clutches are *ukin junk.

Even with heavy duty after market clutch, you will still ride the clutch a heap (and wear it) if your reversing a good load up a hill mate - just don't be unrealistic that an off the shelf heavy replacement are indestructible.
1000 times better than standard, but they will burn plenty (and you will smell it) if you load it up like reversing a load up a hill.
Note to self - drive up your driveway.

I can offer feedback on the Clutch Industries 4 terrain product - excellent!
I carry load, tow heavy and off road hard - product is exceptional.

[whitepanda]

What do you guys suggest as the best heavy duty clutch upgrade? Just purchased a 14 foot jayco camper and we will be towing it around a fair bit, plus we also do some mild off road stuff, and at this stage the clutch was burning just reversing the camper up our driveway.

I had my 07 d4d Sr5 clutch fail at 70000 but as previously mentioned this clutch has been superceded in newer models. I went the full clutch/flywheel conversion by NPC in Brisbane. This is a HD landcruiser clutch with a billet alloy fly wheel. AWESOME for towing or if you have done engine/ power mods! The clutch still has good pedal feel but has so much more positive engagement. Absolutely no shudder.

[mauricem]

What do you guys suggest as the best heavy duty clutch upgrade? Just purchased a 14 foot jayco camper and we will be towing it around a fair bit, plus we also do some mild off road stuff, and at this stage the clutch was burning just reversing the camper up our driveway.

I had my 07 d4d Sr5 clutch fail at 70000 but as previously mentioned this clutch has been superceded in newer models. I went the full clutch/flywheel conversion by NPC in Brisbane.

How much was that worth?

[whitepanda]

It was $2k which included new rear main seal , oils and labour. NPC will supply you the kit only. Which i think from memory was around $1200 ish.