I installed a new Toyota clutch into my 89 4Runner last night and when I went to bolt on the slave cylinder I noticed the clutch fork was about a half inch away from it. (When I removed it the slave was compressed by the clutch fork).

The pressure plate and clutch disc appeared to be a slightly different design but all looked to be the same dimensions, along with the throwout bearing.

Trying to figure out why the clutch fork is so far away from the slave now. Any difference between these parts over the years they were made?

Thanks!

 

Did you install the throw out bearing the correct way?

 

It appeared that it could only be installed one way. Metal wire clip holds it to the fork with the bearing surface facing the pressure plate.

 

Well with the Toyota's simple manual gear box there are very few things it can be.

Incorrect clutch system components installed.
Incorrectly installed clutch components.
Bent and or damaged clutch fork.
Release bearing missing..?

Have you tried moving the fork to see if its stuck and or moving normally..?

3VZ I believe only had one type of 4WD manual gear box through out its service in trucks.

 

Thanks for the ideas guys. Just thought I would update this and say the problem was....there was no problem.

The original clutch was so worn that the slave cylinder was rather compressed by the fork. The new clutch just had a lower finger height due to the disc being thicker.

Just bolting up the slave and pumping the pedal a few times resulted in everything working perfectly.

 

Good deal! Glad you found your problem!