New clutch installed and not working properly

MONCHO6685

MEMBER
1998 TOYOTA TERCEL
1.5L
4 CYL
2WD
MANUAL
165,944 MILES

I'm a beginner. I changed a clutch with a new clutch set but I have the problem that it does not want to apply or apply rough. I have this question, maybe someone laugh or something, but it's possible that the master cylinder clutch is damaged too at the same time? I purge the system with new dot3 liquid, that change, can damaged the master cylinder clutch?

when the car is not running (engine off) the transmission shifts apply, but when I turn the engine on and it apply rough or not apply. I reviewed all the things that I do 6 times with all the information you send to me and other that I found in the shop-key pro program on my college and ask and tell what I do to my teachers and I make everything okay by the book. The only thing that I did not changed was the master cylinder clutch. I put new grease into the transmission 75w 90. 2 quarts and I measure the level until the fill plug is dripping some grease. And that's it. What I left to do? What have I missed? Change the master cylinder clutch.

9 Replies

JACOBANDNICKOLAS

MECHANIC
109,885 POSTS

Welcome to 2CarPros.

Based on your description, either the clutch master cylinder is bad or the clutch slave cylinder is bad. If you pump the clutch several times, can you smoothly shift into gear with the engine running?

__________________________________

After reading your question, my first suspect is the clutch master cylinder. Here are the directions for replacement or overhaul. The attached pictures correlate with the directions.

CLUTCH MASTER CYLINDER

pic 1

COMPONENTS

REMOVAL

1. DRAW OUT FLUID WITH SYRINGE

pic 2

2. DISCONNECT CLUTCH LINE
Using Special Service Tool (SST), disconnect the line. Use a container to catch the fluid.
SST 09023-00100

Torque: 15 Nm (155 kgf-cm, 11 ft. Lbs.)

3. REMOVE CLIP AND CLEVIS PIN
4. REMOVE 2 MOUNTING NUTS AND PULL OUT MASTER CYLINDER

Torque: 12 Nm (120 kgf-cm, 9 ft. Lbs.)

DISASSEMBLY

pic 3

1. REMOVE RESERVOIR TANK
a. Using a pin punch and hammer, drive out the slotted spring pin.
B. Remove the reservoir tank and grommet.

Pic 4

2. REMOVE PUSH ROD
Pull off the boot, and using snap ring pliers, remove the snap ring.
3. REMOVE PISTON

REASSEMBLY

pic 5

1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER
3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING

pic 6

4. INSTALL RESERVOIR TANK
a. Install the reservoir tank and a new grommet.
B. Using a pin punch and hammer, drive in the slotted spring pin.

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, bleed system and adjust clutch pedal.

________________________________________

Also, here are the directions for removing, overhauling, and replacement of the clutch slave cylinder which can also be bad. The difficult thing is to determine which is the problem. Both can cause this issue, a soft or spongy clutch pedal and so on. Most commonly, you will find a leak at the slave. The master cylinder usually goes bad internally.

_______________________________________

CLUTCH RELEASE CYLINDER

pic 7

COMPONENTS

REMOVAL

pic 8

1. DISCONNECT CLUTCH LINE
Using Special Service Tool (SST), disconnect the line. Use a container to catch the fluid.
SST 09023-00100

Torque: 15 Nm (155 kgf-cm, 11 ft. Lbs.)

2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYLINDER

Torque: 12 Nm (120 kgf-cm, 9 ft. Lbs.)

DISASSEMBLY

1. PULL OUT BOOT WITH PUSH ROD

pic 9

2. REMOVE PISTON
Using compressed air, remove the piston with the spring from the cylinder.

REASSEMBLY

pic 10

1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN
2. INSTALL PISTON WITH SPRING INTO CYLINDER
3. INSTALL BOOT WITH PUSH ROD TO CYLINDER

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, bleed clutch system.

+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++

Let me know what you find or if you have other questions.

Take care,
Joe

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