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Clutch slave working but clutch won't disengage.

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86-95 Trucks & 4Runners 2nd/3rd gen pickups, and 1st/2nd gen 4Runners with IFS

Clutch slave working but clutch won't disengage.

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Old 08-07-2018, 12:06 PM
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Clutch slave working but clutch won't disengage.

I have a 1994 V6 3VZE.
My son was driving the truck the other day. While he was parking, he said he thought he hear a faint pop. He was then not able to shift.
We also noticed that the clutch switch that allows the truck to start was no longer being depressed by the pedal. So we had to start the truck with the bypass button on the dash.

We were able to get the home shifting without the clutch.
We've replaced the master and slave cylinders and bled the system. I can see the fork being pushed by the slave cylinder. Peeking in that fork boot I can see that it is moving. The fork doesn't *appear* to be broken.

We've also tried to make sure there were stray bubbles in the slave cylinder by taking it off while attached to the line and maneuvering it around, then opening up the bleed valve to let fluid come out. We then attached it and tried, but still no shifting joy. We then bled the system a few more times..same problem.

We have also adjusted (to both extremes) the rod on the master cylinder that the clutch pedal attaches to. Obviously one setting barely moves the fork, so now we have it at the other setting, operating the fork as much as the pedal will allow.

We were not having any issues with a slipping clutch or anything before. I replaced the clutch about 70,000 miles ago.

Any ideas?

Last edited by cbeaudin; 08-07-2018 at 12:34 PM.
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Old 08-07-2018, 01:28 PM
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The symptoms sound like the clutch pedal bracket may have cracked due to fatigue. If the bracket has a crack, it will flex and not allow the clutch pedal to fully release the clutch.

Take a good look at the clutch pedal bracket for cracks. It may be hard to see due to the location. Check out this thread: Beware of Clutch Bracket Fatigue!

If no cracks are found, other things will need to be checked.

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Old 08-07-2018, 02:04 PM
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Jake, that was a good thought. I went and looked and don't seen any cracks or much visible play in the bracket. It looks like the switch bracket might have gotten bent, so I was able to bend that back so the clutch is now engaging the switch. I can start it now with the clutch, but I still can't shift..
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Old 08-07-2018, 11:57 PM
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Red face

Well your son heard a Pop !

Is it making any noises that are new ??

Did the clutch release bearing come out of the fork ?

Does the transmission shift when the engine is shut off??

How many miles on the clutch ??

Looks like things need to come apart .
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Old 08-08-2018, 03:46 AM
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Doesn't seem to be making any new sounds. Yes it shifts fine when the engine is off. If I remove the boot and look through the hole where the fork goes, I can still see the retaining spring for the bearing. I think I can feel the bearing still on there.
70K on the clutch.
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Old 08-10-2018, 10:42 AM
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Jake, upon further inspection I found a crack in the clutch pedal bracket. Great tip! Thanks.
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Old 08-10-2018, 02:34 PM
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It can be a royal pain to get down there and really look easy to miss
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Old 08-10-2018, 04:18 PM
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Take some pictures. As you can probably see, this actually comes up pretty often. Your picture will help someone else to know exactly what to look for. (YOU missed it the first time.)
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Old 08-11-2018, 08:47 AM
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Here are pictures of the broken bracket.







Last edited by cbeaudin; 08-11-2018 at 07:40 PM.
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Old 08-12-2018, 10:43 AM
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Yep, those cracks are easy to miss when the bracket is installed, but are easy to see once the bracket is removed from the vehicle.

Thanks for posting up pictures!

It is time to either find another bracket or weld this one up with reinforcements.

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Old 08-12-2018, 12:21 PM
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I think I am going to go with weld+reinforcements.
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