Clutch/Shifting Problem - 2006 4 cyl. 4x4 5 Speed

I need some guidance from you gurus on what this could be:

2006 4 cyl. 4x4 manual, 84K, owned since new. Weather here in W. Oregon isn't too cold (40s +)

A few weeks ago I was taking my son to practice and suddenly I couldn't shift into gear at an intersection. Clutch pedal felt normal, everything seemed fine, I just couldn't shift out of neutral and into gear with the engine running. By starting and stopping the engine, I was able to get out of the intersection and onto a side street. I did some more of this and eventually I was able to start pushing it into gear without much clashing...and by the time I got home (about 5 miles away), it was shifting more or less normally.

Since then, I have been driving it without much incident about 10-20 miles a day for the last few weeks. Today I started having the issue where I couldn't shift into gear again. I've learned to sort of coast and feel when I can shift it into gear again, and I am able to get around without much issue. The difficulty of getting it into gear changes over time. Sometimes it feels completely normal, other times it's impossible...all within the span of a few minutes of driving.

The main symptom besides not being able to shift reliably, is that I hear a "slushy", faint grinding sound when the clutch pedal is IN. There are a few light squeaky sounds here and there, some rattling, etc. When I let the clutch OUT, the noise stops completely.

This has never been a great feeling clutch pedal, and it has squeaked off and on since the first year I bought it. Nevertheless, I haven't ever had a rig where there was a clutch problem and it acted inconsistently like this. Normally it just breaks. What could be the problem here?

Thanks!

 

It sounds like your clutch is broken, or more specifically the pressure plate.

 

Before you dive into replacing stuff, make sure your clutch is properly adjusted, and bleed the system.

The noise you're hearing with the pedal depressed is the pilot bearing, I'm guessing it's smoked. The shifting issue sounds like a worn/damaged pressure plate.

Cost of a new clutch kit ranges from $150 - $400; for stock, go with

$208 AISIN CKT-065 OE Matched Clutch Kit - Compatible with Select Toyota T100, Tacoma

this. Do not get a LUK clutch, there's a history of issues with them. The labor however, will be a lot more ($1000 +/-) if you can't tackle it by yourself. Find a local machine shop and have the flywheel resurfaced at the same time, usually runs around $70 +/-.

Here's a few thread/info links:
R-155 manual transmission information
Replacement Clutch Recommendations
Better clutch for 2TR thread - a nice R&R write-up by @allmotorrex is on page 3, post #42

 

Thanks for the help guys!!!