recurring clutch problem

Hi all, newbie here. I first posted this in a Garage forum and reposted it here, since all the moderators seem to be offline...

When I bought my 2001 Tacoma with 160K miles, it came with a clutch problem: after a lot of clutch use in a short time, e.g. in a traffic jam, the pedal wouldn't come back up and I couldn't change gears anymore. Had the master cylinder replaced, that solved it. But about 5000 miles later, it came back. Replaced master and slave, and it was better, though not perfect; but now another 1000 miles later, same problem again. In all cases, it improves when the car sits e.g. overnight; but it comes back quicker and quicker.

I don't think more cylinder replacing will help. Should I replace the whole clutch assembly? Does a worn clutch fit the symptoms? It now has 170K miles, so it could well be due, but I'd hate to have the work done and find the problem is still there, or comes back in another 1000 miles.

Thanks for any suggestions!

 

Do you ever have to add fluid?

 

Good point, I did check it recently and had to top it up, it was way low. Leak somewhere?

 

That would be my guess. Have someone pump the clutch while you're underneath and look for leaks.

 

You are getting air in the system somewhere. Since you have replaced Master and Slave, I'd guess in the line someplace.

 

Alas, we pumped and pumped, nothing came out, and the fluid level was 100% like a month ago. Can air get in without fluid coming out?

 

It can, generally in the Master.
I guess you could have a bad master, unlikely a bad slave.
If the clutch pivot point up under the dash is worn, the rod that goes to the Master can wobble and cant the rubber piston a little and admit air. Had a Saab once that did that, don't know about a Tacoma. That rod should go straight in and out. If not that area, then you might have a clutch spring issue.
Take it to a specialist that only does clutches and drivelines, UJoints, etc. They will know more than the dealer, who will just put parts in.