Hi Folks
I thought it would be fun to share my progress replacing the clutch release cylinder on my BJ75 single cab. It has a five speed transmission (part 33030-60500).
Two months ago, I noticed that the clutch master cylinder reservoir was discolored and the fluid yucky, so I took a look underneath the truck and sure enough, the release cylinder was weeping. Last week, on a hot day, I started the truck in the parking lot and immediately the truck crawled forward. I shut off the truck and pumped the pedal, which was spongy. I started it up and all was fine again. I had a hunch that the release cylinder was worn out and ready to be replaced.
I could not find the original release cylinder available via Toyota, so I called Sunny at FJ Parts, who sold me a brand new Aisin release cylinder as well as a new brake master cylinder (that’s another project). They arrived quickly and they look great.
I began my work soaking the release cylinder bolts in oil. Above in the engine bay, I removed the clip which holds the hard line to the soft clutch hose. You need a little Knipex pliers to lever that clip out. Before taking it all the way out, I broke the nut on the clutch hard line, using a clutch line 10mm wrench (probably not the right term but you get my gist?). I used a baster to evacuate any fluid in the clutch master cylinder reservoir.
I went below and used a ratcheting wrench in the two bolts holding the release cylinder to the transmission. The first broke quickly, the second was weirdly, eerily slow. I panicked. I soaked it in more oil and checked that I was not rounding the threads. I turned slowly, then the bolt broke free, but only 20% of the bolt came out. The other 80% is still in there.
My two first challenges are finding a replacement clutch hose and secondly extracting that broken bolt. I was thinking of drilling it out. Space is tight. Maybe heat it? Soak it in oil? Use extractor bolts? I’ve never extracted a bolt before so I am in the dark on that.
I thought it would be fun to share my progress replacing the clutch release cylinder on my BJ75 single cab. It has a five speed transmission (part 33030-60500).
Two months ago, I noticed that the clutch master cylinder reservoir was discolored and the fluid yucky, so I took a look underneath the truck and sure enough, the release cylinder was weeping. Last week, on a hot day, I started the truck in the parking lot and immediately the truck crawled forward. I shut off the truck and pumped the pedal, which was spongy. I started it up and all was fine again. I had a hunch that the release cylinder was worn out and ready to be replaced.
I could not find the original release cylinder available via Toyota, so I called Sunny at FJ Parts, who sold me a brand new Aisin release cylinder as well as a new brake master cylinder (that’s another project). They arrived quickly and they look great.
I began my work soaking the release cylinder bolts in oil. Above in the engine bay, I removed the clip which holds the hard line to the soft clutch hose. You need a little Knipex pliers to lever that clip out. Before taking it all the way out, I broke the nut on the clutch hard line, using a clutch line 10mm wrench (probably not the right term but you get my gist?). I used a baster to evacuate any fluid in the clutch master cylinder reservoir.
I went below and used a ratcheting wrench in the two bolts holding the release cylinder to the transmission. The first broke quickly, the second was weirdly, eerily slow. I panicked. I soaked it in more oil and checked that I was not rounding the threads. I turned slowly, then the bolt broke free, but only 20% of the bolt came out. The other 80% is still in there.
My two first challenges are finding a replacement clutch hose and secondly extracting that broken bolt. I was thinking of drilling it out. Space is tight. Maybe heat it? Soak it in oil? Use extractor bolts? I’ve never extracted a bolt before so I am in the dark on that.
