FJ62 with H55F Transmission Stiff and Burnt Smell

[Octave Zangs]

Hi everyone,

Yesterday I drove +150 miles back home in my 1990 FJ62 with H55F manual transmission, that was installed brand new ~30k miles ago. Around 75 miles in my trip, my shifter got super stiff and I had to apply quite a lot of force to shift gear, same force for all the gear. As I got back home, there was a burnt smell.

Today I decided to change the oil for both transmission and transfer case. As I drained both it didn't look that bad, there was some fine metal particles on the drain screw (magnet) of both but nothing major. After putting new oil in both (80W-90) I did a quick test drive, and it was still much harder than usual to shift, but another issue is that I need the clutch pedal to be all the way in with quite a lot of extra pressure to start the car/shift gear.

Any pointers before I take it to a shop? Thanks!

 

[OSS]

My guess is that the clutch actuation is incorrect. It’s not fully releasing. If the clutch disc fully disengages from the flywheel and clutch cover, shifting is easy. If the disc is still partially engaged (due to insufficient actuation) shifting will be a grinding affair.

On a FJ60 which came with a manual transmission, clutch actuation begins right at the beginning of the pedal stroke, right at the top - and it doesn’t require any undue leg strength. It feels normal.

The burn smell may be unrelated to the hard shifting - unless the clutch is always slipping. A slipping clutch will eventually burn and you’ll smell it.

 

[Octave Zangs]

Hi thank you for your quick reply! I actually realized that my clutch fluid was super low... I bled the clutch system and now everything is smooth as butter!

I will keep an eye out to see if I have a leak somewhere.

 

[SteveH]

@Octave Zangs - not sure of your experience level, but recall that the clutch MC will typically leak down the inside of the firewall and peel the paint off, so look below your clutch pedal for wetness or buckled paint. The slave cylinder typically just drips on your garage floor.

 

[Octave Zangs]

@SteveH - you're right I have fluid on my mat below the clutch pedal... Does it mean I should change the MC? Not sure I could see if the slave cylinder is leaking since it's parked on gravel and my engine is already making some oil drips haha.

 

[SteveH]

Yep - time for an MC. Not worth trying to rebuild it, in my world. If you're running FJ60 parts, this might be it: More Information for AISIN CMT032 - https://www.rockauto.com/en/moreinfo.php?pk=1946754&cc=1276589&pt=1996&jsn=434

 

[3_puppies]

IMHO if changing one, just change both the master and the slave

 

[Octave Zangs]

Sounds good thank you all!

 

[kevin in okinawa]

IMHO if changing one, just change both the master and the slave

what puppies said...do both now or in a few months you'll be doing the slave cylinder anyways...