D4D 4x4 - New clutch issue

[jjrossouw]

Hi all, I had a new clutch fitted to my D4D 4x4. After the job last week, it felt great. Pedal was smooth and gear change was smooth, but since Monday the gear change is not smooth anymore (mainly from 1st to 2nd but also 2nd to 3rd). There is also more pressure on the pedal (not as soft when I got it back last week). I had the work done at a Toyota dealership. I had the vehicle back there, but their thoughts were that its the free play on the clutch, but they could not correct it with that adjustment. They then said it must be the gearbox and they will have new g/box oil added this week. But I am not sure if its gearbox. Sound like I should get a second opinion? The clutch was nearly R6k! My vehicle has done 135000 km.

[OOOOMS]

I would take it to another dealership and get their opinion also, even a 3rd.

[Mud Dog]

I'm certain that the D4D has a hydraulic clutch, and it sounds to me to be more of a hydraulic problem than anything else. Maybe a problem with the master or slave cylinders .... is it leaking hydraulic oil (brake fluid in this case) anywhere that you can see? .... Is the fluid level in the clutch hydraulic reservoir still adequate? .... Has the level dropped?

[jjrossouw]

I thought about that last night and had a look. It must be hydraulics, maybe some air in the system. I think they removed the slave cylinder (the one on the gearbox) when they removed the gearbox for the clutch to be fitted. Maybe its leaking to the inside, therefore I can't see physical leaks. At least its not a very expensive part. I hope Toyota looks at this as well. Not sure how to bleed the system myself, but I will take it to Toyota tomorrow anyway. But thanks, I think you are spot on about this.

[jjrossouw]

Ok, seems like the cause of this problem was identified. Upon removing the rubber boot from the slave cylinder, fluid is dripping out. Having a new one fitted now. I hope this fixes the issue. Clutch master cylinder is still fine as no leaks were spotted there.

[Mud Dog]

Ok, seems like the cause of this problem was identified. Upon removing the rubber boot from the slave cylinder, fluid is dripping out. Having a new one fitted now. I hope this fixes the issue. Clutch master cylinder is still fine as no leaks were spotted there.

I hope so too!

[koeka]

Jacques

Let us know what was the problem please! Then we can refer to this for future issues.

Thanks a million

[jjrossouw]

Hi Koeka en ander, hier is my terugvoering...
Toyota changed my gearbox oil as well as the clutch slave cylinder yesterday. The clutch lost hydraulic pressure due to the slave cylinder seals which was worn. Now the clutch feels much better and it is definitely more smooth when changing between 1st and 2nd gears. When I mentioned to the service manager that I suspect a hydraulic fault, he did not hesitate to investigate and had an open-minded approach to the issue. Well done to Toyota.
To inspect: All you need to do is pull the rubber boot away from the cylinder (the one on the cylinder) and see if there are any fluid (will be black due to worn seals) dripping out.
Often when having something fixed, something else breaks and then we are quick to point fingers to the dealers, but I realised that new parts affect old parts due to increased pressure (in this case from the new clutch). Who knows, maybe my clutch master cylinder is next - hope not :) The important thing is to maintain one's vehicle and to build a good archive of information on this website to pinpoint these issues more easily.

[Maverick131]

Jacques,

Kan jy asb vir my sê watter clutch kit jy ingesit: Sachs, Luk-Repco, Toyota...? Sal dit waardeer!

My clutch het van Dinsdag af nou 'n effense shudder as ek wegtrek en dit irriteer my grensloos! :evil:

Groete!

[Mud Dog]

Jacus, you will need to replace the clutch plate, pressure plate and of course the release bearing. This will solve your problem 99% of the time provided that it is fitted correctly ... the only time that it doesn't is if the flywheel is warped / burnt and this is most unusual. More than likely your problem has originated from a worn / burnt clutch or a pressure plate that has become warped or some of the 'fingers' on the pressure plate have become weak and applying uneven pressure.

[Maverick131]

Thanks Andy!

All the items you mention in your post - they included in a clutch kit? Heard it is more expensive when you buy the parts seperately.

[Allan]

Hi, wees baie bly dit is n Toyota, vriend van my se Navara clutch Desember opgepak.... R23560-00 haha gee my n Toyota.....R6000-00 is n druppel

[Maverick131]

:wth: Liewe hemel - hoop daai clutch kan self 'n 4x4 herwinning ten minste doen vir daai geld!

[Mr_B]

It often happens that the slave cylinder gives up after a clutch replacement! Probably because the brake/hydraulic fluid pits the cylinder bore, after the clutch re-do the seals run over the pitted bore and get eaten!

[ChrisF]

Mr D that is a very interesting comment .. something to remember for later use .......

[Mud Dog]

Thanks Andy!

All the items you mention in your post - they included in a clutch kit? Heard it is more expensive when you buy the parts seperately.

Sorry that I only see this now, Jacus .... yes they are all part of the 'kit'. Get a 'Sachs' or 'Luk - Repco' kit .... both are good. (that is if you're doing it yourself or having it done at a mechanical workshop .... if the vehicle is still under warranty or service plan you're stuck with the dealers). A kit should be in the region of about 1k (Midas or Autozone).

[Maverick131]

Noted, thank you Andy for your feedback!

Luckilly for me, the shudder is gone now... Think the Big Man upstairs helped out a bit