Manual trans Noise TSB complete. New issues *now with video*

So I got my clutch pedal and master cylinder replaced under a tsb addressing the creaking sound. The noise is fixed but I have 2 new issues.

Biggest issue is my truck wont start unless i absolutely mash the clutch to the floor. Sometimes i need to press it a few times for the safety switch to activate.

Then something else I notice that alarms me is the amount of flex in the pedal bracket or maybe the firewall.

Can anyone confirm that the bracket holding the pedal and master cylinder is supposed to flex this much? Looks close to 1/4 inch.
I saw it when under the dash and pressing the pedal with my hand.

I will be going back to the dealer for what I hope is a bad safety switch.

 

I haven't noticed the flex you speak of, but yeah that safety switch business isn't right. It's also going to be a bitch getting the truck into 4Lo.
That magic clutch start cancel switch on your dash will save your arse when it comes to starting though!

 

I found the clutch switch falling out of my truck after they worked on my pedal one time. But sounds like you've looked at it, simple design of theres an issue it's pretty obvious

 

Yea I just comfirmed getting into 4Lo is an issue as is starting the truck (without using the Clutch start cancel). It takes a few attempts at bottoming out the pedal to get anything related to the switch to work. Back to the dealer it goes. I should have just greased the thing myself instead of having them mess with it.....

 

Yeah man, I don't remember if there's an adjustment for that bottom switch in the service manual and I don't have access to the PDF right now...shit.

There is a link on TW for the whole 3rd gen manual somewhere....

 

The clutch safety switch probably needs to be adjusted. As far as the flex im not sure good luck.

 

@Burro09 ; here you go, check out post #81 for the SM link -

https://www.tacomaworld.com/threads/2016-tacoma-service-manual-availability-pdf.485229/

You can't preview it as it's too large.

Anyway, one of the headings is "clutch". The whole adjustment procedure is in there. I've done it, as my free play was off.

Again, brain no worky if there is a safety switch adjustment in there.

 

This. ^^^

 

I had the "Tacoma squeak" after my first winter. Someone gave me advice here to use disc brake grease, well over year and a half no noise through another winter and two summers....

 

I had my pedal assembly replaced a few months ago and the exact same thing happened. Its not the switch but i believe the "plate" that comes in contact with the switch is off a bit---maybe a manufacturing issue? Regardless, i got tired of having to mash it all the way to the floor, so i took a felt pad i had laying around the house(the ones that you put on the bottom of furniture to prevent it from scratching your floors) and just took some electrical tape and wrapped it around 2-3 times. Problem solved and haven't thought about it since.

 

I did see the plate actually. There is a tab on the pedal itself and a plate that holds the actual switch to the pedal bracket assembly.

My pedal touches the floor, but the switch does not get fully depressed. There is alot of sideways flex in the pedal relative to the switch "nub" as well, so this is probably why it works when I floor the pedal differently. The tab kind of hits the switch at a differemt angle depending on how you press the pedal. Now that I have seen it, the pedal is very cheap. So much flex and prone to noises with that ball and cup clevis design.

Regardless, its at the dealer now. I want them to fix it since it was fine before the TSB. I hate others working on my vehicles, but this is a practically new truck with a warranty.

 

The clutch pedal is a bitch to R/R because you have to work under the dash. I'm sure the monkeys at the service garage weren't real happy about doing that jobs and just threw it together. Who knows if it was done correctly. I did the disc brake grease job on the pivot bolt and bushings and its been very smooth for over a year. It was a huge PITA to get the bolt back in due to a fairly cheesy pedal bracket. None of the bracket edges are deburred, so you are likely to cut yourself open on them too.

There are several small things I have corrected that should have been 3/36K warranty items, but I only use the dealer when I absolutely have to, because I don't trust them.

 

I shouldn't have looked at this right before taking my truck in for the squeak issue... maybe i should say its fine and just have them pay attention to the broken fan.

 

Here is a video I made of the flexing.

The dealer fixed the issue with the switch by just bending the switch bracket with some pliers LOL, works great.In the they process adjusted the pedal to where the master cyl. is always slightly depressed, no freeplay. Bye bye throw out bearing and components. Im fixing that.

Can anyone do me a solid and compare the flexing with yours?

 

Well as an update, I took the lower dash apart and torqued all the fasteners to spec on the clutch pedal assembly to body. Still flexes, nothing is stripped. Im going to assume normal.

Also, as expected, they broke both clip holders on the kick panel, so no more side clips to hold it snug lol.

 

Yep, especially with the colder weather, those plastic pieces are junk. As a rule of thumb, i never try to take any panels off if its too cold outside. Glad they 'fixed' your issue.

 

I haven’t had the TSB done but my truck has had issues with pushing the clutch in far enough to start it.

 

Wouldn't be surprised if we see a lot of 2018s with this "issue" I'm assuming the pedal assembly production tolerances are off a tad and not coming in contact with the switch.

 

Wow I'm sure that mount is not supposed to move that much. I'm betting that they misaligned something and that's what's causing that flex. I just made a video of mine and there is absolutely no movement at all.

I've had my pedal creak from time to time but it doesn't bother me too much.

https://youtu.be/_mFnJLdLYvA

 

Holy crap mine DOES NOT do that. Solid, like the second vid in here.