99 4Runner 5spd clutch / tranny issue(s)

[davemw]

Hey folks,
I'm a new owner of a Supercharged 99 4Runner with 198k on it. So far it's a fantastic truck but I have a few questions that I can't seem to find answers to through search.

The transmission was rebuilt at 40k and the clutch was replaced then.

1. I have a hard time downshifting to 1st while the truck is moving. I can shift through the other gears without a problem and it shifts fine when I'm stopped. Is this normal behavior? I'm used to being able to shift into any gear at anytime (minus revers) in most manuals. It feels as though there's some sort of blocking device in the way until I get down to maybe 3mph.

2. I'm not sure if the clutch is going out. It engages about 2 inches off the floor. It feels solid otherwise but seems too low for my liking.

3. I also had a situation the other day after some light wheeling where I was sitting at a light with the clutch depressed. I could not shift into any gear and when I lifted my foot, the clutch only came up about half way. I pulled it up with my toe, depressed it again and everything was fine from there on out. I hadn't experienced the problem before that and haven't since.


Thoughts?
Thanks!
Dave

Here's a pic because... well, everything is better with pics!

 

[AKAndy]

I think the difficulty in downshifting to 1st is normal, at least in my experience. However, 1st is a low enough gear that I never felt like I needed to downshift any lower than 2nd. I've always figured its better to let the brakes take the majority of the wear and tear instead of the transmission unless I'm on a hill.

I had the same problem with my clutch, and had to replace the master and slave cylinders to get the clutch back to normal.

 

[Doozi]

My thoughts...
1. This could be a symptom of worn synchro's. I don't remember having this issue with my 5-speed 4Runner.

2. Sounds like it might be getting there. According to your numbers, you have about 150k on that clutch.

3. I agree that this might be an issue with master/slave cylinders. Check fluid level in the master, look for any obvious signs of leakage, and if you don't see anything you might try bleeding the system.

 

[sportscarfan]

Get some Redline Synthetic MT4 transmission fluid and the shifting should get easier. 1st is still a little tough to get in mine when cold, but once it's warm no problem. The MT4 made a huge difference compared to Amsoil which is what the previous owner had put in.

With the clutch pedal issue, you might want to take it apart and have a look. It's fairly easy to get the clutch pedal assy. out. What has probably happened is there is supposed to be a plastic bushing between the hefty spring and the notch in the pedal. The plastic eventually breaks and then the spring starts eating the pedal. I had to weld in the area the spring chewed out and then I tried a new toyota plastic bushing - it broke again in one day. I had to pull it apart and then made my own bushing out of some round nylon stock I had. I've seen other writeups here or at yotatech where people take the factory spring out and replace it with a regular extension spring from the hardware store.

The engagement point is somewhat adjustable where the pushrod meets the pedal. Also adjust the clutch switch or your cruise won't work.

 

[madbomber08]

I have read before on here or yotatech that if you shift into 1st if you're traveling over 10-15mph it can damage the synchro. I think it's just natural for it to be like this, but I agree it can be a nuisance sometimes.

 

[A.Wilson013]

These guys are alllll business around here.

I will be the guy who adds nothing to the thread, but tells you how nice your truck is!

Now I know what mine will look like with steel wheels and duratracs! Which bumper is that...?

 

[davemw]

Guys, thanks for the replies. I'll take some time tomorrow and check the fluids and adjustment, and report back.

Also, thanks for the compliments, the bumper is custom built as ar as I know. The truck is in good shape but I need to do some boy work on the driver's side. Needs a front door and fender after the PO slid off the road into a fence.

 

[Doozi]

Sportscarfan's post made me remember that when I first bought my Gen3 the clutch pedal would stick sometimes and I ended up replacing a nylon bushing in the pedal assembly... it was a dealer part and about $8.00, but fixed the problem completely.

 

[scottyb]

Another vote for the plastic bushings. My clutch started to not return all the way after I bought it. I did the spring mod from yotatech and it's been great since.

FIXED!! Stupid PLASTIC clutch pedal bushing - YotaTech Forums

Great looking truck!