Hey gang, been a while and I hope you’re all doing well! I’ll get right into my problem:

Since I’ve owned my 85 4Runner, the transmission has always been difficult to shift into first and second. I assumed the synchros were going out and it would need a rebuild at some point.

About a year ago the input shaft chipped some teeth and I sent the trans off to Marlin for a rebuild. Due to life, work, and kids I just got it running again about a month ago.

While I was in there, I replaced the flywheel, clutch, pilot and throw out bearings, and all clutch related hydraulics and soft lines.

Parts installed:
Clutch master cylinder: Aisin CMT-003
Clutch slave cylinder: Aisin CRT-001
Stainless braided clutch line: LCE 1054060
Clutch kit: Aisin CKT-024
Flywheel: LuK 6092925127


Turns out it’s still tough to get into 1st and 2nd. I re-bled the clutch system last week and re-adjusted the clutch pushrod last night. It’s doing better but still not smooth. I’m also completely out of travel on the clutch pushrod - the pushrod ends inside the threads for the pedal clevis thing.

Is there a different clutch master cylinder with a longer throw? The only parts I didn’t replace was the clutch fork and it’s pivot, but I see two part numbers for both of those on yotashop. How are they different? Do you guys see anything I’m missing?

Thanks for any help!

 

Your description of events still sounds like air in the system . First adjust the rod under the dash to where it takes up the free play and back it off about a 1/4 turn to where there is just a bit of end play. Every so often I have to mess with these bleeding a simple clutch master and slave to get all the air out. Also, check the rubber hose down below to make sure it free flows and is not starting to come apart internally. Kinks in the metal line anywhere?