SOS - Clutch Problems - 5 speed Swap

[Coffey50]

Hello All,

I just finished swapping an R150F into my 1994 SR5 4runner. The donor trans came from a 1988 or so 1st gen 4runner.
New Aisin Clutch
New Aisin Pilot Bearing
New Aisin Throwout bearing.
New Aisin Pressure Plate
New Aisin Master Cylinder
New Aisin Slave Cylinder
All stuck together with the clutch alignment tool.


Upon completing the wiring portion of the swap I was ready to back the truck out of the garage and take her for a test drive.
I first tested first gear and as I let out the clutch she nudged forwards.
Reverse not so much..... I put the 4runner in reverse and let the clutch out gave her gas and she moved. I gave it more gas and it didn't move any faster. Th clutch starting smoking.

I stopped the truck and shut her down. Letting the clutch cool off.
I re-bled the clutch hydraulic system to check for air. No air bubbles.
I then read about adjusting the Master Cylinder rod, after doing that the truck is worse than before.

Now I can "dump the clutch" at idle engine speed and the truck does not shut off.

Can anyone please help me figure out this issue ? College starts back this week and I would love to get her fixed in time.







I bought an Aisin Slave according to rock auto it works for year models 1989-1995. The donor truck was a 1988. I dont know if this could be an issue so later today I'll be picking up an 1988 slave Cylinder.

Also I'll link a youtube video showing the play the slave cylinder has back towards the engine.
Showing the position of the master cylinder when the clutch pedal is not being pushed down.
It has quite a bit of travel back into the slave cylinder and I think that might be a problem.

https://youtu.be/leVKCC28esg

 

[bentos1]

Did you figure out the issue? Was it the slave not pushing the clutch fork in enough? I did see a cheap trick years ago where someone extended the slave push rod with a cut off of a bic pen. I guess you could always try something like that as a temporary solution to see if the issue does in fact remain with the slave push rod.

 

[Jixxer6]

Not totally sure on this one since I don't know the differences between the two manual transmissions. I will say it looks like there is still air in the system by how easily you can push that slave in. Also I don't like how easily you can move that shift fork. It tells me it's not making good contact with the pressure plate. This could be because the fork is not compatible with that clutch or transmission. Please correct me if I'm wrong but that trans came out of a 4cyl truck right?


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[Coffey50]

Not totally sure on this one since I don't know the differences between the two manual transmissions. I will say it looks like there is still air in the system by how easily you can push that slave in. Also I don't like how easily you can move that shift fork. It tells me it's not making good contact with the pressure plate. This could be because the fork is not compatible with that clutch or transmission. Please correct me if I'm wrong but that trans came out of a 4cyl truck right?


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I havent had time to screw with it since school started. 3000's and 4000's level psychology courses; however, the transmission came out of 88 with a v6. R150f is the v6 trans, the W56 was the 4cylinder trans.

Also I almost destroyed a pinion flange due to Marlin Crawler sending me the wrong pinion flange. They sent me a new one I'm just waiting to put it on.

I'll upload pics of the carnage in a moment.

 

[Coffey50]

i havent had time to screw with it since school started. 3000's and 4000's level psychology courses; however, the transmission came out of 88 with a v6. R150f is the v6 trans, the w56 was the 4cylinder trans.

Also i almost destroyed a pinion flange due to marlin crawler sending me the wrong pinion flange. They sent me a new one i'm just waiting to put it on.

I'll upload pics of the carnage in a moment.

 

[Jixxer6]

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Ouch! That could have been all kinds of no fun if it killed the pinion.


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[Coffey50]

Ouch! That could have been all kinds of no fun if it killed the pinion.


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You're telling me. You can see in the photos I think the material is from the pinion seal lip *Heavy Duty from Marlin Crawler* and no the splines. I can turn the rear axle with the OEM flange, but the force from my hands is not equal to engine power so lets hope I'm not out looking for a 3rd Member.