Relatively new clutch, now harder to press ~500mi later

I recently installed a new clutch on my 2004 Tacoma extracab 3.4 4x4. I used all new parts from marlin crawler. While I was there, I replaced both the master and slave cylinders as well as a steel braided clutch hose. I replaced just about every clutch related piece I could. For the first ~600 miles, everything was great. The clutch pedal was slightly easier to push than before, smoother, felt more linear, overall better than ever. It was like this was until last week. I was driving some dirt roads, not very aggressively and as I was leaving. The clutch started to feel about 20% harder to press. It almost felt dampened, where if I pushed slowly, it felt pretty close to normal, but if I stepped on it quickly as if I was just switching gears, it was extra firm. It is hard to tell exactly, but the pressure plate seems to react a bit slower than it did previously.

Any thoughts on what might have gone wrong?

I have done a quick look over to see if something got wedged around the clutch fork, or slave cylinder, but nothing stood out. I plan to bleed the hydraulic system to see if that helps anything, but I am skeptical. It seems odd for a change like this to happen suddenly rather than over time as bearings and other parts start to wear. The system is still drive-able, but I just have to press harder, and take my time shifting. Any other diagnostics I can do without dropping the transmission again would be ideal.

Thanks

 

Look around the clutch bracket it is a pain to get under there .

Maybe something vibrated loose from the Master Cylinder install

 

Off topic but where did you get the braided clutch hose?

 

I'll double check tonight, hopefully I missed to put a pin all the way back in.

Also the clutch hose is available here
https://www.marlincrawler.com/clutch/hydraulics/steel-braided-clutch-line-kit

I'm not sure if it is actually much better, I just figured I would switch it out if I was doing it anyway

 

The return spring on the clutch pedal commonly causes issues and could be your trouble. The v6 has a weird coil return spring. If you can get your head under there with a flash light you can see it. The plastic bushings on it wear out and the spring starts wearing a deeper notch in the tab it sets in on the clutch pedal. When this happens it causes all kinds of problems. Could easily be causing your problem. It would be easy to check, just remove the spring, and see if the problem goes away. To remove it just put a screw driver in-between the spring and the bracket, and pry it loose. Careful, it might go flying when it comes out. You can run without a return spring. The pedal might not come up far enough to let your cruise control to activate, but you will be able to tell you if the spring is your problem.

Even if the coil spring doesn't end up being your problem I suggest replacing it with a linear one because the coil spring will eventually cause you problems. Get a brake pedal return spring, or a clutch pedal return spring for a 4 cylinder, and put it on instead. Easy to install. There is a rod with a grove in it on the pedal, one end goes on, and a tab with a small hole in it up under the dash that the other end goes in. Since the 4 cylinder models use a linear spring the connection points are already there. I don't guarantee this will fix your problem, but it's easy to do and inexpensive.

 

Dear TheRealMcCoy,

You have an interesting problem here since the clutch system in these first generation Tacomas is hydraulic, which means the clutch pedal is hydraulically controlled so the clutch pedal is going to feel the same no matter what shape the clutch is in. Something must of happened to the hydraulics in regards to your truck to make it start behaving the way it does.

Hope that helps,
Paul

 

Unfortunately it doesn't seem to be an issue with the bushing in the clutch pedal assembly. I removed the entire assembly, inspected and re lubricated the bushing assembly, and removed the torsion spring (I plan on replacing it with a linear return spring). I am still seeing the same symptoms (Stiffer/dampened when pressing on the pedal, slightly slower return and slower clutch response).

 

When the Clutch was installed was the fit of the release bearing checked ..

Did it get knocked loose on install so it is riding slightly sideways ??

That might impact the return but should not effect the pressure stroke

Any problems getting it into gear??

Any smell of burning clutch??

All the Parts were from Marlin Crawler every thing??

I think all new Fluid You did use DOT 3 brake fluid.

It almost sounds like the Master or slave failed I know new parts but it does happen

 

I'm not sure how to check the fit of the release bearing. I actuated the clutch fork with my hand and it slid smoothly along the transmission input shaft if that is what you are asking?

I don't think it was knocked loose on install, since it worked fine for over a month. That being said, how would it get knocked sideways? It is on the input shaft, so it would have to come off of that to change direction correct?

No problems getting it into gear, It was a bit tough before the clutch replacement, but I found the pilot bearing to be partially seized and a new one seems to have fixed it.

Yes everything was from Marlin, all the way down to replacement flywheel bolts and slave cylinder bleed nipple covers.

I did use DOT 3 brake fluid, but it was not a new bottle (maybe 2 years old?) could that cause issues?