1st Gen 4Runner clutch issues

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Joined
Nov 24, 2025
Threads
3
Messages
8
Location
Williamsburg, VA
Hey gang, first post over here but I’ve been directed here a bunch from google searches. Tons of knowledge!

Since I’ve owned my 85 4Runner, the transmission has always been difficult to shift into first and second. I assumed the synchros were going out and it would need a rebuild at some point.

About a year ago the input shaft chipped some teeth and I sent the trans off to Marlin for a rebuild. Due to life, work, and kids I just got it running again about a month ago.

While I was in there, I replaced the flywheel, clutch, pilot and throw out bearings, and all clutch related hydraulics and soft lines.

Parts installed:
Clutch master cylinder: Aisin CMT-003
Clutch slave cylinder: Aisin CRT-001
Stainless braided clutch line: LCE 1054060
Clutch kit: Aisin CKT-024
Flywheel: LuK 6092925127


Turns out it’s still tough to get into 1st and 2nd. I re-bled the clutch system last week and re-adjusted the clutch pushrod last night. It’s doing better but still not smooth. I’m also completely out of travel on the clutch pushrod - the pushrod ends inside the threads for the pedal clevis thing.

Is there a different clutch master cylinder with a longer throw? The only parts I didn’t replace was the clutch fork and it’s pivot, but I see two part numbers for both of those on yotashop. How are they different? Do you guys see anything I’m missing?

Thanks for any help!
 
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