I replaced a clutch in my 91' 4 Runner V6 3.0L 4x4 in Feb of 06 due to my wife learning how to drive a manual tranny. I have had no issues until now. I am hoping you fella can help diagnose the problem. When I first heard the "noise", I had just returned from a long road trip of over 50 hours on the highways of western US. The "noise" sounds of metal on metal grinding in combination with a squealing belt sound and only happens when I pushed the clutch [B]in[B]. The next morning, I couldnt get it into gear unless the engine was off. If I started the motor while in first gear and the clutch completely depressed, the "noise" happened and I was able to slowly start driving. I only did this to get it to my buddy's shop. While the motor is on, I cannot push the shifter into any gear and reverse grinds. So, we replaced the throwout bearing because the clutch looked good. (stupidly, we didnt remove the anything to see the clutch plate itself!). At first it seemed to work only to hear a sort of "clang" and again with the same problem. We bled the lines to no avail and even cut a 4"x4" square to see if everything was working properly, of which it seems to. I removed the master and slave cyclinders and there was horrible brown gunk in both of them and brown gunk sludge in the bottom of the master. So, I ordered a master cyclinder rebuild kit and am hoping it will fix my problem.

Any help or advice would be appreciated.

 

If you're getting proper deflection out of the slave cylinder and you've got a new throw out bearing, I'm wondering if you replaced your pilot bearing.

A bad pilot bearing will cause issues like you describe - applying the clutch and the driveline still wants to turn.

 

pilot bearing??? where is it, how do I replace it, where can I buy it and how much do they cost?? Thanks for the info in advance.

 

it is on the crank where the front output shaft goes into the crank. while you are there,looht as well replace the rear main seal. oh, to remove the pilot bearing, chop up a candle and feed the pieces into the pilot bearing hole till it fills up, then take a clutch alignment tool and beat in some more wax, keep feeding it wax and it will force the bearing out. use old bearing to put in new bearing.

 

is it the bearing inside the flywheel?

 

It's inside the end of the output shaft from the crank.