This is an odd problem (I think) and I'm hoping someone here will have some ideas about fixing it. I have a 94 3.0 5sp 4runner. I put a remanned engine in less than 2000 miles ago with a lot of help from these forums. I put in a new clutch and bearing and had the flywheel turned while the engine was out.

The problems is, when the engine is cold, the clutch pedal is soft. It is soft enough that I would adjust it, except that after a few miles the pedal gets harder. It stays hard until the truck has been sitting a long time, like overnight. Right now I have the pedal adjusted to split the difference between the two extremes but it bugs me. I have replaced the fluid and the bled the cylinders but that made no difference.

Could this be a problem with one or both of the cylinders or did I screw something up when I installed the clutch?

 

Well before you go and buy a new m/c, try bleeding it first. Might save yourself a couple bucks.

 

Yes, yota4runna, that is exactly what it is doing.

I have already bled it and it didn't help. Replacing the master cyclinder is an easy job. I'll do that and hopefully that will fix it.

 

Well, it's nothing to do with engine operating temps. The two are unrelated. What's probably happening is the fluid pressure is building up as you drive and use the clutch....not unlike when you pump brakes. So, it sounds like air in the system. Look for leaks around the m/c and slave. Check where the the clutch pedal engages the m/c piston at the firewall inside the cab and under the carpeting for signs of fluid leakage. If nothing their, look at the slave and your fluid lines.

 

yeah, check the MC. ive had 2 go out on me in the same year. . its nasty when they start to, cuz your driver floor is covered in brake fluid. the truck starts smelling like it too... after i fixed it the 2nd time, i accidently spilled a cup of super strong coffee, and that covered up the brake fluid smell... but even after 2.5 years, when its hot, i can smell the coffee. anyways, check your mc. if anything pressurize it and see if the pressure holds.. i think you can do that with brake lines and clutch lines....