Well here is my story. First off i have a 87 4runner sr5 with a 5 spd manual. The clutch master and slave were all reaplace 800 miles ago. I started to have a problem with the clutch not fully disengaging. When i would push the clutch all the way to the floor with the truck running and try to shift into first it was super hard but yes i could get it to litterally pop into gear. secong gaer is only a little smoother but not much. Also reverse grinds if i try to shift into it. to check and see if the clutch wasnt fully disengagin i jacked up a rear wheel (stock open diff) put it in first and got the wheel spining then i pushed in the clutch and still the wheel spins and you cant stop it.

So by then i new my problem the clutch wasnt fully disengaging. I went down to napa and picked up a slave first. Istalled it and no difference. And yes i am possitive all the air is bled out. I looked at the master cylinder throw adjuster that connects to the peddle and mine is already adjusted to the max.
Next i got under the truck and measured the the distance from a point on the slave to a point on the fork when the clutch was pressed. then i tooke a nut that was smaller than the slave shaft that was roughly .25 inches tall and put it between the fork and the slave push shaft. then prssed the clutch all the way in and measured. The measurement was the same telling me that the fork was all the way and it couldnt go any farther because it should have pushed the extra quarter inch but it didnt.

So at thsi point i am really puzzled at what is happening because i have had clutches go out befor but they usaully just start to slip not just start to not disengage all the way. so at this point i decide it is probabley somethign inside the clutch becuase even with the fork at maximum travel it doesnt disengage. I can easily put in a new clutch as i have a lift but i wanted to get some oppinions on what some of you other guys and gals might think my problem is. I dont want to go out and buy a whole clutch kit yet because i dont think its is burned out i think it might be somethign else in there. But anywya if i have to take it all apart i will put it in anyway.

So what do you think is wrong with it and what clutches would you recomend? I am running 32 inch mud terrains right now but plan the do a sas and 35's with 5.29 and lockers in the near future so i need sometihgn that will hold up.

 

Are you sure you are adjusting it correctly? If no thread is visible on the adjustment rod then that is the opposite of what it should be. Are there any leaks in the line or where the lines attach to the cylinders? It could also be a pilot bearing where the transmission shaft goes into the flywheel. If you do a clutch job then make sure you change and grease that bearing.

 

im sure i am adjustind it right i have tried all posible positiosn it can be adjusted into. and there is absoultly no leaks anywhere. So i have pretty much narrowed ti down to soemthign inside of the clutch bell

 

Check the metal plate that attaches to the firewall from the clutch pedal. These crack sometimes & allow enough flex for the clutch to not fully disengage.

 

ya but thta wouldnt be it the fork is maxing out in the clutch. the clutch is a far disenaged as it will possibly go but still doesnt disengage. So if there is no more travel left in the plate it doesnt matter if anything is wrong with the pedal beacause im still getting maximum travel in the clutch.

 

I had an issue like this once on a Ford truck. When I replaced the clutch somehow the throwout bearing got wedged in the spring fingers on the clutch. Had to take it apart and get a new clutch and bearing...at no cost since it didnt have any miles on it and I had bought the lifetime warranty parts. Just alot of extra work.