KDJ120 Clutch Replacement DIY - Words of Wisdom?

[limestonecowboy Lurker Find all posts View Profile Close limestonecowboy]

Howdy y'all,

I'll be spending my weekend replacing the clutch in my 2009 KDJ120 after my clutch finally gave up the ghost last weekend. I've not done any drivetrain work in my previous vehicles, and this is my first attempt at work on a 4WD. I've done quite a bit of my own work in the past using what I've learned from my Dad, my own mistakes, forums and youtube. I've bought the Toyota Service Manual and read it, looked for youtube vids and scoured this forum for tips/how to from previous posts but come up pretty empty.

I plan on doing the work in my carport, machining the flywheel, replacing the rear main seal - standard stuff. I'm also using a standard clutch rather than a HD. I mainly drive on the beach or on bush tracks in SEQ with no plans for hauling a trailer. I've been getting mixed advice on HD vs Standard, and decided that Standard will suit my needs. And, if i do the work myself, I can change to HD if the need ever arises.

Before I make a big mistake, is there something about the 120 that keeps people from tackling this job themselves? Any hints or advice? If i find the time during the replacement, i'll take good notes, photos and try to contribute my lessons learned.

Cheers boys

Jeremy

[carco Advanced Member Find all posts View Profile Close carco]

Petrol or diesel? I think the diesels have a DMF and have read that they can't be machined. Insane price to replace.

[limestonecowboy Lurker Find all posts View Profile Close limestonecowboy]

Sorry - diesel - what's a DMF? All the mechanics quotes I've received have included machining the flywheel, which I thought was the only thing that needed to be machined during the replacement?

Thanks for the reply

[groeschel Member Find all posts View Profile Close groeschel]

Sorry - diesel - what's a DMF? All the mechanics quotes I've received have included machining the flywheel, which I thought was the only thing that needed to be machined during the replacement?

Thanks for the reply

DMF stands for Dual Mass Flywheel, a kind of shockabsorber in the clutch to reduce shock loads at low revs on the drive train.
The material cost for mine was around $750 a few years back, came with install to around $1000.
You need to get the gearbox out to do, which probably would be easiest with hoist and a few additional hands.

Cheers
Mike

[carco Advanced Member Find all posts View Profile Close carco]

Let us know if it can be machined.
The Exedy site says it can't be done but perhaps they're just trying to sell a solid wheel kit?

[limestonecowboy Lurker Find all posts View Profile Close limestonecowboy]

Damn. I didn't read that in the Service Manual. I'll let y'all know what I find!

After a search of several other forums, there's no agreement on the flywheel in a Prado, and it looks like Hi-Lux guys are replacing their DMF with a Prado flywheel... I'll post pics when I get this sorted.

Cheers boys.

Jeremy

[groeschel Member Find all posts View Profile Close groeschel]

Let us know if it can be machined.
The Exedy site says it can't be done but perhaps they're just trying to sell a solid wheel kit?

I cant comment whether the DMF can be machined or not but would expect that the additional spring etc would make the machining difficult.
I think it is similar like machining disk rotors; the cost plus the possible less than optimal result might or might not offset the cost of the parts (and the labour in case you need to do it again)

There are different opinions about whether it is a good idea to replace a DMF with a solid one.
I would only replace a DMF with a solid one on a vehicle in which I keep the revs relatively high to avoid shock loads on the drive train at low revs.
For normal road use for me that defeats the purpose, as I want to keep the car in the economical low revs as much as possible in order to reduce the fuel consumption.
Thats why I keep DMF on vehicles which I use as a daily driver

Cheers
Mike

[carco Advanced Member Find all posts View Profile Close carco]

Yes lots of comments but no help with first hand experience. My searching also noted there were two different pressure plates to suit the differently stepped wheels. One wheel has a 0.5mm step and the other is much deeper. Can't fit one pressure plate on the other wheel if you see what I mean. Very confusing, Prado V's Surf V's Hilux etc .

Damn. I didn't read that in the Service Manual. I'll let y'all know what I find!

After a search of several other forums, there's no agreement on the flywheel in a Prado, and it looks like Hi-Lux guys are replacing their DMF with a Prado flywheel... I'll post pics when I get this sorted.

Cheers boys.

Jeremy

[batto Junior Member Find all posts View Profile Close batto]

Hi jeremey, my 2007 1kd has a standard flywheel, this thread is the first ive heard of a possible dmf setup in these. Change out is pretty straightforward, gearbox out (check service manual or acs clutch site for procedure to release throw out bearing on 6 speed). Pressure plate off, flywheel off then rear main seal. Always machine flywheel no matter how ok it looks. Then install is reverse of removal. A bit awkward to do at home on stands but certainly do able, had mine out for a box rebuild.
Cheers Batto.

[limestonecowboy Lurker Find all posts View Profile Close limestonecowboy]

Thanks for the input Batto - it looks straight forward, but figured I'd ask where the traps were.

Cheers Jeremy

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

i picked up a new flywheel for my 2008 6sp D4D and it was a solid flywheel
call your toyota dealer with your vin number and they should be able to tell you what the flywheel is
i'm fairly certin it's a std type flywheel

have a good look at the snout for the bearing , if that's damaged it will need a new bell housing
as they are not repairable with a sleeve & larger bearing like the KZ version

[batto Junior Member Find all posts View Profile Close batto]

Razorback81, had forgotten about that, though if snout is not too badly worn you can actually get away with cleaning up with emery tape(tip given from a clutch workshop). Worst thing is that if new bellhousing is needed the whole box needs to pulled down.
Cheers Batto.

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

i will need to do mine at some stage, and have been trying to work out how to fix that (if it's worn )
maybe able to add some of those 2 part mix it putty (the right 1 for the snout) and massage it back into shape

i'm still trying to see one out of the car so i can work something out
if i had to replace the bell housing it's no issue as it's not my daily driver

can you see the sleeve when it's in the car ?? i haven't checked

i know Brett M did his quite a while back and had to swap bell housings and it was like $950 something
maybe we should bet the part number & see if there is any here or they have to come in

as it has part of the gears in it i would suggest any fix would need to be done without any welding involved as it will distort the centre of the housing
and to do any machining you would need to dismantle the box anyway

mind you that is all WORST case , if it hasn't seen much mud and is still clean inside it should be fine with a clean up !!

[limestonecowboy Lurker Find all posts View Profile Close limestonecowboy]

Thanks for the tip Razorback!

[David ff Lurker Find all posts View Profile Close David ff]

Hi guys

Hi Lurker.

Could you please help me with the torque on the flywheel screws?.

I have a Toyota prado 120 series, 2004 diesel