TOY: Stumped by a clutch

["Allen Dickenson" <fort.knox@xxxxxxxxxxx>]

Ok, I must be doing something wrong here.  I've replaced everything but the
clutch line itself and the freakin' pedal and it still doesn't feel right.

Here's the problem:

My clutch used to grab almost right off the floor like normal.  Then, at
GSMTR, I smoked the clutch pretty good going up Upper 2 to the point that
until it cooled down, it wouldn't grab at all.  Once it cooled down, it
started grabbing like normal again, except that it didn't start to grab
until the last inch or so of pedal up-travel (near the top).


Here's what I've done to try to fix it:

1.  Replaced the clutch disk, t.o. bearing, pilot bearing, pressure plate
and flywheel with a Downey SuperClutch 2.
2.  Replaced the master cylinder and slave cylinder with Toyota parts.
3.  Bled the system thoroughly.
4.  Adjusted freeplay according to the factory manual. - after adjusting the
push rod on the new M/C, freeplay feels o.k.
5.  Checked the clutch release point according to the factory manual.

Step 5 involved starting the truck, slowly shifting into reverse without
pushing in the clutch until I could hear the gears starting to contact.
Then I pushed the clutch in and listened for when the gear noise stopped.
This point should be at least 1 inch from the floor.  It seemed to be fine.
However, the clutch still doesn't seem to grab until the pedal is almost all
the way up.  The manual doesn't really say what to do to adjust the clutch
engagement point.  The engagement is solid when it does grab, but it's not
grabbing just off the floor like it used to.  Am I missing some sort of
adjustment here?

Any ideas?  I'm stumped.  I've even considered taking it to the dealer to
see if they can figure it out.

Thanks!


Allen Dickenson      TLCA #6318
http://www.geocities.com/Baja/Trails/8895/
1995 4Runner UnLimited - "Fort Knox" - Lifted, Locked, Geared, Warn'd,
Snorkeled & Dented.