1PZ flywheel trouble

[Petzel]

I have a 1991 PZJ77 with a R151R tranny and I keep hearing random scratching/clunking sounds that seem to be coming from my bellhousing area. My first suspicion is that the springs that hold the dualmass flywheel together are breaking. It only makes sound sometimes, an then it is quiet for a week or two or six! This morning it sound so bad that i pulled over and all of a sudden there was no noise until i drove home from work(small scratchy sound). I called Ens Industrial and they stock a replacement flywheel(uber expensive) because it is a common part to replace on the mine vehicles! As far as i know, the springs are not available from Toyota(Ens confimed this).
I am trying to figure out what to do to fix this and not spend $1,700 every 150,000km. Anyone come across this problem? Is there a solution? I have heard of welding the flywheel. Anyone done this? Is there another one piece flywheel that will work instead of the two piece?
My truck is a Japanese import with 195,000km

 

[roscoFJ73]

I have a 1991 PZJ77 with a R151R tranny and I keep hearing random scratching/clunking sounds that seem to be coming from my bellhousing area. My first suspicion is that the springs that hold the dualmass flywheel together are breaking. It only makes sound sometimes, an then it is quiet for a week or two or six! This morning it sound so bad that i pulled over and all of a sudden there was no noise until i drove home from work(small scratchy sound). I called Ens Industrial and they stock a replacement flywheel(uber expensive) because it is a common part to replace on the mine vehicles! As far as i know, the springs are not available from Toyota(Ens confimed this).
I am trying to figure out what to do to fix this and not spend $1,700 every 150,000km. Anyone come across this problem? Is there a solution? I have heard of welding the flywheel. Anyone done this? Is there another one piece flywheel that will work instead of the two piece?
My truck is a Japanese import with 195,000km

First you need to confirm the problem by visually inspecting the flywheel.It might be the thrust bearing
I would advise against welding it. Five cyl need some fancy balancing and its probably why they are 2 piece.
Others have done it with no adverse side affects.

Try Dave Stedman as Japan4x4,he is in the vender list. I imagine he would be able to shave a fair bit off that $1700 price
Or see Crushers,he might have one laying around

 

[PZJ70]

Hi Petzel,

I had a 1pz dual mass flywheel fail and it does sound like what you describe. It progressively gets worse. I'd pull the rubber boot off the clutch fork and poke a long magnet into the bottom of the bellhousing (engine off obviously) and see if there are any bits of springs floating around.

Like you, a replacement dual mass flywheel was too expensive (especially to only have fail again). So I replaced my clutch with a custom version using OEM parts! It consisted of a 1HZ solid flywheel, a HZJ78/9 clutch plate to gearbox splines and flywheel diam. The only difficulty was that the 1HZ flywheel is not as thick as the 1PZ DM version, hence the throwout bearing needs to be longer to make up the difference. I ended up looking through some bearing catalogues and eventually found one..... Off a toyota coaster mini bus with a 1HZ funnily enough.. Not sure but it might even use an R151 'box?

Not sure where you are or what is available to you but I hope this helps. If you need part numbers I may be able to chase them up.


NB: I'd advise against weldingup the DM flywheel without changing the clutch plate to a sprung clutch plate, as the 1pz'suse a solid clutch plate with no allowance for torsional shock loading (as the DM flywheel takes care of that)

 

[Petzel]

PZJ70: yes please...send me some part numbers!

I have road trip down to Moab Utah planned to for May 11 that i need to have the truck ready for! I have taken the tranny out and found a spring to be BROKEN. I have already welded the flywheel and am getting it balanced right now. What do you think would happen if i had a slid flywheel and solid clutch? Do you think that using my welded flywheel and a HZJ78/9 clutch plate would work? Then i would not need a different thowout bearing?? However, a HZ clutch may not bolt up to my flywheel.

I am near Vancouver, BC, Canada

 

[Kroll]

Do you know the part number for the throw out bearing off of the coaster mini bus?

 

[Petzel]

Who me??? I dont have a part number for ya....sorry