Trouble with clutch slave cylinder

[Rube]

i have a 1984 fj60 but am having trouble with replacing the clutch slave cylinder. I know that the part differ from early vs late fj60s. i got what I thought was the correct part (aisin crt-019) but the shaft is far too long to put inside the clutch fork. Notable that my clutch fork does not have the external return spring that I expected it to. Im probably missing something simple, but need help figuring out where I went wrong (other than buying someone else's basket case).

That said, if anyone has an inspection cover for sale, I'm in the market.

 

[Ian Crawford]

Re-use your old one!

 

[Ian Crawford]

I just had the opposite, my new Beck-Arnley unit ordered for my '83 had a new pushrod that was too short. I just reused the old pushrod with the new slave.

 

[Rube]

The old one is too short and won't compress completely due to the rubber boot.

Is it not odd that an early fj60 doesn't have the external spring on the release fork?

 

[Ian Crawford]

Im not sure I follow why the old pushrod will not work?

My early '83 has an external spring on a small bracket that utilizes the slave mounting bolts and your fork has the small hole on the outside for it.

 

[bhk]

Is it not odd that an early fj60 doesn't have the external spring on the release fork?

It's only odd if it came from the factory that way.

This is what yours should look like (minus the gunk). This was the configuration up to 4/85.

It appears that at some point your bracket and return spring were discarded. The 4/85 and later clutch release has an internal spring, so the external is no longer needed. The later release also mounts directly to the bell housing.

I'd guess that someone installed a later clutch release and cut down the old (longer) push rod to account for the different mounting position without the bracket. Were there one or two bolts holding on your old clutch release?

 

[884runner]

I'm having this same problem and I don't have an old cylinder to use the rod from. I have 2 1983 FJ60's and on my other one the rod seems to be a bit shorter than the new one I received in the CRT-019, although it is threaded and not the 1985+ style. So does anyone have a solution? Maybe try to make a rod from a 10mm bolt?

 

[cruisermatt]

I'm having this same problem and I don't have an old cylinder to use the rod from. I have 2 1983 FJ60's and on my other one the rod seems to be a bit shorter than the new one I received in the CRT-019, although it is threaded and not the 1985+ style. So does anyone have a solution? Maybe try to make a rod from a 10mm bolt?

In the case of the OP, which looks like there was no posted resolution - I can see what his issue was clear as day.

He has an +85 bellhousing with a pre-85 clutch fork. The clutch forks and slave cylinder pushrods are both different lengths. Someone did some mix and matching in his truck. Installing a +85 bellhousing into a pre-85 is also not a great idea because the angle of the crossmember is different, it can all fit together (I've seen it done) but will prematurely wear engine and transmission mounts.