Worn snout on 6sp manual due to release bearing (thrust bearing). Is this common?

[winniliss Avid PP Poster! Find all posts View Profile Close winniliss]

Hello,
I have a 2009 120 series D4D with a 6sp manual gearbox. I got my clutch replaced in Mar 2014 and after 12 months the release bearing (thrust bearing) started making a noise.
I got the clutch replaced and it was noted the snout on the end of the gearbox had a worn groove in it where the release bearing slides up and down on (see photo)



So I have three questions:

1. Is this a common problem?

2. What is the likely cause/s? (I have my theories) and

3. What have others done to prevent this?

Now I spoke to the Roo and he put me on to:

BHSS-TBS Brake & Steering Remanufacturing
(07) 3620 6555
38 Smith St
Capalaba QLD 4157

They turn down the shaft and fit a stainless steel sleeve. They will need the customer to supply the release bearing. If the customer drops off the front part of the gearbox the cost will be about $360 and 1-2 days to complete.

Is there other places that can do this?

Cheers

Winston.

[D4Dforme Senior Member Find all posts View Profile Close D4Dforme]

Mate it's a very common thing to happen.........Poor design.

if you are in Darwin still you could go and see Casper at ATSEA Engineering Berrimah explain what you need and i'm sure he will do it........Very good machinist and does a lot of work with heavy diesel stuff.

Dan

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

i could get it done for you but i am in Adelaide

let me know if you need

[t303 Senior Member Find all posts View Profile Close t303]

There is a mob in the states that make these sleeves, they attach with a couple of grub screws and loctite shaft fit, but I can't for the life of me remember their name. IIRC they make one for the Tacoma/Hilux over there and I believe one fits the Prado. Anyone remember who they are?

edit, found the post: http://www.pradopoint.com/archive/in.../t-13280.html?

[winniliss Avid PP Poster! Find all posts View Profile Close winniliss]

i could get it done for you but i am in Adelaide

let me know if you need

Cheers,
Just waiting on ATSEA to get back to me.

I also contacted that mob in USA t303. They don't do a kit for the D4D.

[azzss Member Find all posts View Profile Close azzss]

Every time i service mine, i remove the inspection plates on the bell housing, and spray silicone spray on the shaft and bearing. Seems to help abit and make clutch lighter.
Cheers

[Walky88 Member Find all posts View Profile Close Walky88]

The company i work for imports the sleeves from America.

Its a very common occurance across a large range of vehicles.

I can't think of the exact name however will have alook at work when i get there in the morning.

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Yes common problem on the 6 speeds when used as offroaders.
This is exactly why I avoided it & went auto.
Average design, alloy wears easily, you cannot remove & change it like the r151 5 speeds, which was steel, but the front cover was easily removable. Now it's part of the bell housing, dumb!
Dust & water & mud & water ever else u have to throw at it gets in & wears it, There are holes in the bell housing.
I have found they do clean up & operate ok.

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

Does the same thing occur in the V6's, or is it typically related to the diesels?