I am having problems with the clutch completely disengaging and the clutch pedal being very stiff. I have done the following:

1. Checked pedal bracket for cracks. It is in fine condition.
2. Adjusted push rod on Master Cylinder. Pedal Free Play
3. Bled the system. Fluid was very dark.
4. Replaced the Slave Cylinder.
5. Bled System again
6. Adjusted MC push rod again.
7. Checked Shifter socket. Great condition.

I am about to replace the Master Cylinder but just want to see if anybody can tell me how far the rod on the slave cylinder should extend when the clutch pedal is pushed? Right now it is only extending about a half an inch.
I have searched for this answer in many related posts but the only answer I can find is 1.5-2" in one post. I just need to confirm that is true.

 

1/2" sounds about right.

Have you been into the clutch to see if there are any internal issues? Did this start suddenly or was it tied to some event or maintenance/repair?

 

I have not been into the clutch yet. Just going through the fsm trouble shooting order. This 4runner is new to me but the po said it had been going on since he got it, about 5 years and 100k ago. Clutch does not seem to slip.

If 1/2" is good then I might as well prepare myself to do a new clutch kit. There is a squeak from inside the bell housing when depressing the clutch. This is with the motor NOT running. I removed the fork boot and tried to see if maybe the fork was bent/cracked but it spears to be working fine. Maybe spring(s) teeth bent or something??

 

That could be it. You won't really know until you get in there unless your have one of those cameras in a tube~

 

Just an update for anyone reading this in the future...

I replaced the MC and bled the line using the ten pump method instead of my mighty vac. Got all of the air out. The pedal did seem to lighten up a bit and the slave does extend a very little bit more. Something was still not right so I ordered a marlin clutch and dropped the tranny to have a look.
Everything looked fine even after taking the clutch out though the plate was a bit worn. However after looking at the flywheel more closely it was clear that it was in a real need of resurfacing due to heat/stress cracks. I took it in and the machinest said it hadn't been steped correctly last time. It is supposedly good now. The pilot bearing is shot as well which probably explains the fact that it was hard to get into first gear.
Anyway, I will give it a try with the new flywheel and new clutch kit. I also found a tranny with about 150k less miles for cheap.