Toyota 1KZ-TE Diesel Solid Single-Mass Flywheel (SMF) Clutch Kit - Hilux Surf HiAce 4Runner Prado

ships in 3-4 weeks from the date of purchase.

Product Overview

Premium dual mass to solid flywheel conversion clutch kit compatible with 1993-2005 Toyota Hilux, Surf, and Prado models equipped with 1KZ-TE 3.0L turbo diesel engines. Available in two performance levels to match your driving needs. This comprehensive conversion kit eliminates the problematic factory dual-mass flywheel system and provides superior durability, improved power transfer, and significantly reduced maintenance costs.

Choose Your Clutch Performance Level:

• Standard/OEM 1KZ-TE (320 ft-lbs): OEM-replacement grade for stock to mildly modified engines. Daily driving and light towing.
• Heavy Duty (419 ft-lbs): Performance-grade 4Terrain Ultimate with ER2 technology - Modified engines, heavy towing, large tires

Comparison

Specification	Standard/OEM	Heavy Duty
Clutch Diameter	260mm (OEM size)	275mm (Upgraded size)
Torque Capacity (Rated)	320 ft-lbs (434 Nm)	419 ft-lbs (568 Nm)
Torque Capacity (Peak)	380 ft-lbs (515 Nm)	524 ft-lbs (710 Nm)
Clutch Plate Technology	Organic friction material	Dual friction with Aramid
Pressure Plate Design	Standard casting	Spheroidal graphite + ER2 grooves
Heat Dissipation	Standard	Enhanced (ER2 grooved design)
Recommended For	Stock engines, daily driving, light towing	Tuned engines, heavy towing, 35"+ tires
Power Rating	Up to 180 HP / 320 ft-lbs	Up to 250+ HP / 520 ft-lbs

Which Variant Should You Choose?

Choose Standard/OEM if you have:

• Stock 1KZ-TE engine (130-147 HP, 245-253 ft-lbs)
• Mild modifications (exhaust, intake, minor boost increase)
• Daily driving with occasional light towing
• Stock tire size or up to 33" tires
• Budget-conscious but want reliable OEM-quality replacement

 

Choose Heavy Duty if you have:

• Modified 1KZ-TE with turbo upgrade, intercooler, or tuning (180+ HP)
• Frequent heavy towing (trailers, boats, caravans over 3,000 lbs)
• Large tire upgrades (35" or larger)
• Extreme off-road use with an aggressive driving style
• Want maximum torque capacity and heat resistance
• Planning future performance upgrades

Standard/OEM Key Features:

• Complete Conversion System: Includes solid flywheel, cover assembly, clutch plate, and thrust bearing
• OEM Replacement Grade: Designed to meet or exceed factory specifications for stock applications
• Superior Durability: Eliminates failure-prone dual mass flywheel design
• Organic Friction Material: Smooth engagement with excellent wear characteristics for daily driving
• Cost-Effective: Best value for stock to mildly modified engines

 

Heavy Duty Key Features:

• Patented ER2 Technology: Grooved pressure plate increases torque capacity by 60% while improving heat dissipation
• Dual Friction Clutch Plate: Aramid material (same as bulletproof vests) on flywheel side for extreme fade resistance
• Spheroidal Graphite Casting: 300% stronger than standard casting with anti-burst protection
• High Clamp Load: Enhanced clamping force maintains grip under extreme conditions
• 275mm Upgraded Diameter: Larger friction surface area for superior holding power
• 2-Stage Balancing: Precision balanced to eliminate vibration at all RPM ranges

 

Technical Specifications

Standard/OEM:
Part Type: Dual Mass to Solid Flywheel Conversion Kit
Clutch Diameter: 260mm (OEM specification)
Spline Configuration: 21T x 29.8mm
Flywheel Step: +0.5mm
Torque Capacity (Rated): 434 Nm (320 ft-lbs)
Torque Capacity (Peak): 515 Nm (380 ft-lbs)
Friction Material: Premium organic
Ring Gear: The original ring gear must be reused

Heavy Duty:
Part Type: 4Terrain Ultimate Performance Clutch Kit
Clutch Diameter: 275mm (upgraded from 260mm OEM)
Spline Configuration: 21T x 29.8mm
Torque Capacity (Rated): 568 Nm (419 ft-lbs)
Torque Capacity (Peak): 710 Nm (524 ft-lbs)
Friction Material: Dual friction - Organic + Aramid
Pressure Plate: Spheroidal graphite casting with ER2 grooves
Heat Dissipation: Enhanced with patented ER2 groove technology
Includes: Cover assembly, dual friction clutch plate, thrust bearing, spigot bearing

Fitment

Year Range	Toyota Model	Engine
1993-1997	Hilux KZN130 / KZN165	1KZ-TE 3.0L turbo diesel
1997-2005	Hilux KZN165 / KZN185	1KZ-TE 3.0L turbo diesel
1993-1995	Hilux Surf / 4Runner KZN130	1KZ-TE 3.0L turbo diesel
1995-2000	Hilux Surf KZN185	1KZ-TE 3.0L turbo diesel
1996-2002	Land Cruiser Prado KZJ90 / KZJ95	1KZ-TE 3.0L turbo diesel
1993-1996	Land Cruiser KZJ70R	1KZ-T / 1KZ-TE 3.0L turbo diesel
1995-2004	Hiace KZH100 / KZH106 / KZH116	1KZ-TE 3.0L turbo diesel

Important: This kit is designed specifically for vehicles equipped initially with dual-mass flywheels. The original ring gear from your dual mass flywheel must be removed and transferred to the new solid flywheel during installation. Professional installation with proper flywheel resurfacing and ring gear press-fitting is mandatory.

Installation & Maintenance

Installation Difficulty: Advanced/Professional
Tools Required: Complete transmission removal tools, torque wrench, clutch alignment tool, flywheel holding tool, ring gear press equipment, dial indicator for flywheel runout check
Professional Installation: Strongly recommended - requires transmission removal, ring gear transfer, and precise torque specifications

Installation Notes:

• The original ring gear must be carefully removed from the dual-mass flywheel and pressed onto the new solid-mass flywheel
• New flywheel bolts are required and must be torqued to 82 ft-lbs in proper sequence
• Flywheel runout must not exceed 0.002" (0.05mm) when checked with a dial indicator
• Consider replacing the rear main seal, spigot bearing, and hydraulic clutch line during installation

 

Frequently Asked Questions

Q: What's the main difference between Standard/OEM and Heavy Duty variants?
A: The Standard kit is an OEM-replacement grade solution for stock engines with organic friction material and 320 ft-lbs rated capacity. The Heavy Duty 275mm kit features an upgraded diameter, a dual-friction Aramid/organic clutch plate, an ER2 grooved pressure plate, and a 419 ft-lbs rated capacity (60% increase). Heavy Duty is essential for modified engines, heavy towing, or large tires.

Q: Can I upgrade from Standard to Heavy Duty later?
A: Yes, but it requires purchasing the complete Heavy Duty kit including the 275mm flywheel. The Heavy Duty conversion uses the larger flywheel pattern. If you're planning performance upgrades or heavy use, we recommend starting with Heavy Duty to avoid having to replace the clutch twice.

Q: Why should I convert from dual-mass to a solid single-mass flywheel?
A: Dual-mass flywheels in 1KZ-TE applications are notorious for failure between 80,000-120,000 miles, causing expensive repairs. Solid single-mass flywheel (SMF) conversions eliminate this failure point, provide superior durability, and cost significantly less than dual-mass flywheel replacement.

Q: Will the Heavy Duty kit make my clutch pedal too heavy?
A: Despite 60% higher torque capacity, 4Terrain Ultimate clutches are engineered to maintain good pedal feel with fine modulation control. The high clamp load is achieved through intelligent pressure plate design, not excessive pedal effort. Most users report pedal feel similar to or only slightly firmer than stock.

Q: What's included in each kit, and what additional parts do I need?
A: Both kits include a cover assembly (pressure plate), clutch disc, thrust bearing, spigot bearing, and alignment tool. You must reuse your original ring gear. Additional recommended parts for both: rear main seal and hydraulic clutch line.

 

Why Choose Solid-Mass Flywheel Conversion for 1KZ-TE?

The Smart Alternative to Expensive Dual-Mass Flywheels: Toyota's 1KZ-TE turbo diesel engines were initially equipped with dual-mass flywheels in many markets, particularly in the Japanese domestic market (JDM) Hilux Surf and import Land Cruiser Prado models. While dual-mass flywheels provide excellent vibration dampening, they are notorious for expensive failures and cannot be resurfaced during clutch replacements.

The CI Premium solid mass flywheel represents over 60 years of Australian clutch engineering expertise, specifically designed for the demanding torque characteristics of the 1KZ-TE turbo diesel. This conversion mirrors the factory specification used on UK-market Toyota 4Runner models, which came standard with a solid flywheel.

Built for Turbo Diesel Durability: The solid steel construction handles the 1KZ-TE's 343 Nm (253 ft-lb) of torque with ease, providing superior heat dissipation during towing, off-road driving, and extended highway use. The single-piece design eliminates the internal-spring failures that plague dual-mass flywheels, particularly in heavy-duty applications.

Understanding the Trade-Offs: While solid mass flywheels offer superior reliability and cost-effectiveness, drivers should understand the differences. You may notice mild transmission gear rattle at idle when the clutch is engaged - this is entirely normal and does not indicate a problem. Pressing the clutch pedal eliminates this noise. Clutch engagement may feel slightly firmer compared to dual-mass systems, though most drivers adapt quickly and appreciate the more direct mechanical feel.