05 hilux clutch shutter

Shuddering can be cured by just slipping the clutch for a while, put the hand brake on select a high gear slip it till you smell it burning. Now i know people will knock this but it does work and without causeing damage.
Chris

Have tried this method, although unintentional. Whilst backing a loaded trailer up a hill the clutch slips very easy and produces a very stong smell, made no difference whatsoever to the initial problem. Even taking off at lights with excess clutch slip seems to have no effect either.
The fact the new clutch unit has the same issue, I would think its a pressure plate is not well matched to the size of the clutch, this is a design issue, and would presume only fixable with an aftermarket unit with increase pressure.

Mine April 05 D4D 60K now, has shuddered since new. Every service I'm told all is normal and noise when cold all OK. About 20K throw out bearing was replaced but they didn't machine flywheel as I asked to stop shudder. I also had squealing on takeoff which I put down to spigot bearing but they could not fault it. Upon pickup I ask for someone to come for a drive with me, we didn't leave the dealer as squealing was very apparent. Amazing how they can hear and see problems when they are in your car with you. While waiting for parts I dropped my driveshaft on Pacific Hy. They left one bolt out of the centre bearing on shaft. Got towed back they were very apologetic. I could have got any loan car I wanted that day.Anyway new driveshaft, diff, spigot bearing and finally machined flywheel. About 5K later noise when cold in throwout again bad shudder mainly when and cold squealing again on takeof. In for 60K service to-morrow see how I go.

Chaps something to consider is this.
If your fed up with poor warranty results, take it to a clutch specalist.
Or your local mech, and ask them to do a coarser grind on your flywheel, and the pressure plate.

This can help "bed in" the clutch, and wear the high spots off the clutch plate (the disc with the friction material).
Often (but not in all cases), the shudder is a result of hardened glazed over high spots on the clutch plate that havnt been worn off in the bedding in process of normal driving when the car is new. Thus they are now glazed, and "shudder" instead of taking up smoothly.

Shudder can also be from friction material properties, particularly when they are damp and cold, and also from oil soaking, or overheating, which someone before mentioned slipping the clutch to heat it up.
I would not reccomend such action due to its results of glazing up and further irritating the problem.

I can appreciate the idea behind it, but in essence, your best off removing the clutch plate, sanding off the high spots that have glazed, (they will be obvious on the plate when its out), and then after deglazing the flywheel, and pressure plate, or doing a coarser grind on them putting the pressure plate back on, and ensuring the clutch spring fingers are all even, and not irregular, as this too can result in shudders as well.

Normal driving should bed in a properly setup clutch, if your really gentle with them, they can take some months to really bed in properly.

This might not fix your problems with warranties and the hoops the dealerships make you jump thru, but hopefully, you may understand whats going on a little better.

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