Hey guys! I have a 86 Toyota 4x4 pickup with a 22R 5 speed manual. I just replaced the clutch and flywheel, throw out bearing ect. The clutch keeps slipping and it's driving me crazy. I've bled it more times than I can count, replaced the master cylinder a year or so ago. I just replaced the slave a month ago. The clutch slips more in hotter weather for some reason. It engages at the last bit of the pedle release. I also noticed the it likes to slip most in third gear and up. Sometimes it will slip for a second or two and reenguage without adjusting the throttle, almost as if the clutch lost contact with the flywheel for a split second. I am at a loss as to why this keeps happening. I can find no leaks along the clutch line either and the rear main seal was replaced while I was in there for the clutch. Any suggestions would be appreciated! Thanks!

 

Is there any freeplay in the clutch pedal? You can try adjusting the rod from the clutch pedal to the master cylinder. Maybe it is adjusted too tight and not allowing the clutch to fully engage.

 

You went to all the trouble to change a clutch and did not change the master and slave cylinders.

Did you compare the old clutch parts with the new ?? So many boxed wrong kits put together with returned parts.

What brand clutch ?

Clutch bracket broken??

 

pressure plate my be too worn. anything hydraullic is going to make it not release, not make it slip. once the fork/throwout bearing is off pressure, it's 100% the job of the pressure plate pressing against the flywheel to hold the clutch. if it's slipping, i say the problem is in there, and yes, that means you have to split it open again to diagnose.

 

I've tried adjusting it both ways. When I got enough free play in the pedle, it slipped worse. Right now there isn't any free play but it's the best I could get it.

 

I did change both the master cylinder and slave prior to digging into the clutch. Pretty much tried everything I could to avoid having to take the tranny off.
I used an exedy clutch kit. And compared parts.
When you are speaking of the clutch bracket, do you mean the pedle bracket? I've heard that actually causes the opposite problem of the clutch not disengaging.

 

Is it possible that a new pressure plate would go bad so quickly?

 

If it somehow got oil on it it would slip.

Pressure plate would be able to be cleaned, but disc would be finished.

 

Clutch disk put in the correct way?

 

it could have some debris or something keeping it from seating right, but like i said, only way to find out what is wrong is to split it again and look it over so it doesn't happen again. did you have the flywheel resurfaced? worn deeply where the clutch rides?

 

Before you remove the tranny, check that the slave cylinder is releasing all the way. That will rule out anything hydraulic and pedal adjustments. If you can get a small amount of free play at the clutch fork, then the problem is with the clutch itself. It is either getting oil on it, the pressure plate is bad, or the flywheel was machined to deep to the point where the clutch disk is set too far in from the pressure plate.

It might be worth opening the bleeder screw or even unbolting the slave cylinder before removing the transmission to see if that suddenly releases the clutch fork. If so, then you either have something keeping pressure on the hydraulic system or a faulty slave cylinder that is keeping pressure on the clutch fork.

There is also a chance that the clutch fork/throwout bearing is occasionally jamming up somehow and holding the clutch slightly open, so that is worth checking when you have the transmission out.

 

crack the bleed screw, then if that does nothing, you know it's time to split it apart.

 

Master and slave cylinders are not too expensive. I would recommend replacing them as well.

 

first, this happened two years ago. second, the OP did replace them. third, don't replace parts without verifying that they are non-functioning.

 

How did this end? I am curious to know what the root problem was.