clutch adjustment issue

[RHON]

I've just replaced the clutch master and slave cylanders , bled the system, and adjusted the slave push rod to spec. per the FSM, also adjusted the master pushrod, my problem here is that if you reach down and pull up on the clutch pedal ( only maybe 1/2" it will ccome up ), the next time it is depressed there is a few inches of travel that goes away after a few pumps - kind of like brakes that will pump up because they are out of adjustment, pretty sure the slave push rod is correct and i've played with the master cylander push rod with no effect- could it be the return spring on the pedal is worn? or maybe the return spring on the clutch fork?

[rchalmers3]

Are you saying that when when the pedal is at rest, you can pull it upwards 1/2" to the upper stop?

And then you loose pedal travel after operating the pedal a few times, leaving the height about 2" from the upper stop?

Is that correct?

If so I have these recommendations:

1) Your spring pulling the pedal back up is too weak. You need to replace or retension the spring and have the pedal return to it's proper upper position reliably. The master cup boot slides in the rod OK I assume?

2) After the pedal is returning properly, re-check the pedal pushrod and make sure there's a very small but important bit of gap between the master cup and the pushrod when the pedal is all the way up. Adjust if needed.

3) I'd rebleed the system with a buddy operating the pedal, 'cause on the LHD models the clutch line has a long horizontal run that traps air and can be a bugger to purge. Put a pint through it if you have to.

4) If non of the above works, you are probably looking at a defective master. I can't think of any other reason you would loose the operational height of the pedal.

Good luck and let us know what you find,

Rick

[RHON]

yes , when the pedal is at rest, it can be pulled up another 1/2" or so, that's when I found the excesive travel issue- a couple of pumps and it seems okay and stays that way the master came from SOR and is OEM toyota. Anyway havn't had time last couple of days to look at it- but I will report back should anyone have this same problem, - and thanks for the advice.