Clutch Pedal Won't Return

09' 4x4 6spd

Clutch pedal won't return. Went to adjust it and the plastic part on the pedal side of the adjustment rod appear to no longer be connected. I can't really see how it connects and so far parts schematics i can find don't really show how it connects.

Little help posting me in right direction.
TIA

 

Adjusting it won't help, it's a hydraulic clutch line, it should self adjust all the way down until the clutch disc is at the rivets. The only ones that need occasional adjustment are the old cable ones

If it wasn't returning on it's own then usually something in the clutch line is leaking or the clutch unit itself is bad

But if the pushrod fell apart you might have to get that straightened out first

 

The pedal side of the adjustment rod which is round and plastic is no longer attached. In order to loosen the adjustment but i had to put a wrench on the square nut (not sure it's a nut) as we as the rod nut. The end the adjustment rod threads into is not attached.

 

Pretty it's a ball-and-socket joint? Can you just push the ball back into its seat and snap it back together?

Did you try to pull the clutch pedal up with your toe when it wasn't returning? The ball end may have popped out on its own

 

I can lift the pedal and spring pops it back up but there is no way to make adjustment as it's not connected on the pedal side.

I can't get a good look at how it connects.

I by accident completely unthreaded the adjustment rod from that pedal side part. It doesn't appear to be broken but I'm not sure.

 

Does the master cylinder push/force this part back into the pedal side after you lift your foot off the pedal?

 

If the threaded end came out because you backed it off too far you're going to have to get it threaded back in somehow. It will be a pain in the butt. Might have to pull the whole assembly out and do it on the bench

 

Yes and also the pressure from the clutch keeps it seated in the pedal

But there should be some kind of catch that snaps it together

Honestly I'm not super familiar with the master/pedal end of things on a 2nd gen. Ive done tons of clutch work on lots of different cars but not much on the hydraulics for 2nd gen tacomas

 

I threaded it back together without much of a struggle because it's disconnected on the pedal side. I'll see if I can "pop" it back into the socket so to speak. Seems like that would happen when you push the pedal down but maybe not. I don't know.

 

Yea you can push it back together with foot, as long as the ball is lined up.

But like I said, don't be surprised if there's still a problem somewhere else causing the pedal to not return

 

The 'ball' just kinda sits in the socket in the arm. There's no snapping in or anything. I swapped mine to all metal FJ parts, and had to take that end off the M/C rod to get the pedal wiggled out of the bracket, so hopefully you put everything back together correctly. (Without managing to actuate the clutch without the pedal's leverage, you'd have to have the hydraulic system inop to get it in or out any other way than assembling in situ)

If it's still not returning, I've had mine 'stick' to the floor before, when it was super cold... although I'm guessing it's probably not in the 20s in Houston? I got rid of my accumulator, partially because that's supposedly the cause of that issue. But unless it's cold as hell, that's probably not your huckleberry, and you probably do have a hydraulic issue somewhere... but if you're getting into the hydraulic system, I'd strongly recommend deleting the accumulator anyway.

 

I need to change my location as I'm now in West Los Angeles by the beach so it's for sure not cold that is the problem. I'm wondering if the Master Cylinder is the problem since it appears that the rod is not pushing back against the pedal. I looked at it last night. I'll have a look again tonight or in the morning.

 

Well pedal flat on floor, tried to pump some fluid into system but it won't draw any from the reservoir. I'm assuming the master is shot. Slave is dry but rusty. Did get a little fluid out that was real dirty. No fresh fluid will draw in.

So on my motocross bikes i reverse bleed the brakes. is that possible on the valve at the slave?

 

Speaking from first hand knowledge of 1st gens, I’ve had spring fatigue/failure cause the pedal not to return. All I had to do was replace the spring with another that would work. I’ve also had the pump cup on the master cylinder fail causing a dead pedal, it wouldn’t actuate the slave or clutch. Had to pump several times to create enough pressure to shift. The big difference between the two problems was not being able to shift. I’ve also had the stupid plastic bushings wear out at the hinge point on the clutch pedal assembly, but I don’t recall that caused any problems. Again this was all on my 1st gen so YMMV. The biggest challenge is crawling under the dash on your back. Save some headache and pull the drivers seat, but remember to disconnect the seat belt wire connectors.

 

Oh yes, I'm only 5'10 195 and getting under dash is not easy.

I'm pretty sure it's not going to work but I'm going to hook vacuum pump up and see if I can suck some fluid into the system. Just need a few more days out of it.

Any experience using vacune pump on these trucks?