Clutch issues (1 Viewer)

[martoo]

Gday everyone, completed my manual conversion a couple months ago now, has been all good but I’ve noticed a noise when I push my clutch pedal in while driving, and also the clutch engagement point has risen. It engages when I push the pedal roughly 1/4 of the way. The clutch doesn’t slip, clutch fluid level is where I left it after bleeding the system, no visible leaks. Any idea what the issue could be or where I could start looking? Engagement point was toward the bottom once we completed the conversion. Any help is appreciated!
1HD-FT HDJ80, NPC 900nm hd clutch kit, fresh machined flywheel, brand new master cylinder and slave from ACS.

 

[ppc]

Description you give points to the throw out bearing down on clutch/bell housing.

 

[martoo]

Description you give points to the throw out bearing down on clutch/bell housing.

What could be wrong with that? Siezed or physically worn down? Have read previously about people having issues with a bent clutch fork, could that also be a possibility ?

 

[ppc]

What could be wrong with that? Siezed or physically worn down? Have read previously about people having issues with a bent clutch fork, could that also be a possibility ?

Yes it is very possible. If the fork is bent it could be placing like a side load on the bearing accelerating the wear. With a bent fork, the truck mostly has seen some heavy usage and/or a defective driver .

Some amount noise is inherit to the design. How loud is the noise?

As a point of comparison I have a Infiniti G37 with 96k miles. From almost new I could here the bearing when parked in my garage because of the sound reflecting of the walls. The noise level is still about the same. Never notice it otherwise.

 

[martoo]

Yes it is very possible. If the fork is bent it could be placing like a side load on the bearing accelerating the wear. With a bent fork, the truck mostly has seen some heavy usage and/or a defective driver .

Some amount noise is inherit to the design. How loud is the noise?

As a point of comparison I have a Infiniti G37 with 96k miles. From almost new I could here the bearing when parked in my garage because of the sound reflecting of the walls. The noise level is still about the same. Never notice it otherwise.

Well the whole conversion came used from a rolled 80 series, I recon I’ve done maybe 500km in it since the conversion, the noise is only noticeable with the windows up when pushing the clutch pedal in. It’s noticeable and there’s a slight vibration along with the noise

 

[ppc]

Well, with a conversion that's going to be a hole can of worms.

 

[mudgudgeon]

There is a small amount of adjustment to cab do with the clutch master cylinder push rod length. It will change the pedal position and where you feel the engagement point.

A new clutch fork and throw out bearing are both fairly inexpensive items from Partsouq.com etc
The biggest pain in swapping them is the gearbox has to come out.
If you do swap clutch fork, I'd probably also change the pivot ball too .

Conversion doesn't matter IF it's all Toyota parts, AND all parts match up.
Clutch master and clutch slave cylinders have changed a few times over the years
Try to check that both parts come from the same model year, they aren't all interchangeable

 

[mudgudgeon]

There is a small amount of adjustment to cab do with the clutch master cylinder push rod length. It will change the pedal position and where you feel the engagement point.

A new clutch fork and throw out bearing are both fairly inexpensive items from Partsouq.com etc
The biggest pain in swapping them is the gearbox has to come out.
If you do swap clutch fork, I'd probably also change the pivot ball too .

Conversion doesn't matter IF it's all Toyota parts, AND all parts match up.
Clutch master and clutch slave cylinders have changed a few times over the years
Try to check that both parts come from the same model year, they aren't all interchangeable

 

[martoo]

Gday, still chasing the issue, going to try adjust the clutch pedal tonight and see how we go. Have also just noticed that the clutch fork has a fair bit of pressure on it, doesn’t have any free play, that isn’t correct is it?

 

[mudgudgeon]

Gday, still chasing the issue, going to try adjust the clutch pedal tonight and see how we go. Have also just noticed that the clutch fork has a fair bit of pressure on it, doesn’t have any free play, that isn’t correct is it?

I would expect it to be under some pressure. You don't want any play in the system