T180 2.2 D-4D Another Clutch / Gearbox Question

[Sineda]

Hey guys. I've been crawling around the forums and visited nearly every clutch / gearbox thread out there but couldn't find the same issue as mine.

 

I have a 2007 2.2 D-4D T180 that has covered 119k miles. The clutch biting point is probably an inch off the ground. The clutch in itself is absolutely fine - I've read on here about pedal adjustment (with a diagram of the hydraulic system). The thing is, I find it hard to shift to 1st or from 1st to 2nd; also putting it in reverse. Sometimes it doesn't even want to shift to any of these gears. If I pump the clutch pedal a few times it goes in a bit better but still slightly stiff.

 

I've already replaced the gearbox oil and it made no difference (yes I've used the recommended oil on here).

 

What I found lately is that if I stomp on the clutch pedal aggressively then it changes gears without an issue and ever so smooth, if I don't stomp on the clutch pedal then the gears are stiff and they sometimes crunch in 1st and 2nd only. From third and upwards there are no issues in changing gears. Just 1st, 2nd and reverse.

 

I know this can be a number of things, but I'm puzzled why the gears change fine (like butter) when I apply brute force on the pedal (?). The clutch in itself is not stiff and is the same as on any other car. Oh, another thing. If the car is about to come to a stop (e.g. traffic) and I want to shift down to 1st whilst the car is still moving then it changes from 2nd to 1st as smooth as anything without me having to apply extra force on the clutch pedal! If the car comes to a stop and I put it in neutral and then try to put it back in 1st, I struggle to do so unless I first try other gears and then backing 1st or alternative if I stomp on the clutch pedal harder than you should do.

 

Could this be a slave cylinder? Any suggestions?

 

 

[mrfixer]

I think you have what is called 'clutch drag' where the clutch is not fully disengaging.  The hydraulics would come under suspicion first (master and slave cylinder) but its not impossible that the centre plate is sticking on the splines and not fully disengaging.....

It may boil down to a new clutch and hydraulics...

[Mike169]

Hi Denis.

As Jim above has spoken about I feel this is a hydraulics problem.

When you 'stamp' on the clutch pedal it 'flares' out the seals creating out a 100% good fit where as slowly putting your foot on the pedal/master/slave cylinder and lets brake fluid seep pass.

If you can find yourself a re-rubbering kit for both the master cylinder and the slave cylinder combined then renew the seals.

With respect if this is a hard job for you then get a garage to do it.

Personally first I would change the slave cylinder, cheaper first,, but personably I think it will be the clutch master cylinder and for both of these I hope you have deep pockets as either won't be cheap.

Your best bet is give this man a call, he's a main dealer parts person but gives discount to us on this site, He is known as Kingo, The Parts King, if you phone ask for John Devlin, if he can't help you I give up so to speak. 01978 720074

The number above is the main switchboard so you will have to be put through to him.

He will post many items to you via The Royal Mail or similar.

You will just need to give him your reg. number during normal working hours.

You are welcome to use my name as a contact.

All the best and good luck, Mike.

[paulcap]

It's always worth trying the very simplest thing. Manually pull the clutch pedal up and see if it changes the biting position. The pedal return spring weakens, the plunger in the master cylinder never returns to the home position and the braking circuit never gets topped up from the reservoir. 

[Sineda]

Thank you for the prompt response and apologies for the delay in my response as I've been away.

I've taken note of your advice and I really hope it is just a slave cylinder. The clutch and flywheel were all replaced (along with a new engine under warranty with Toyota) at 65k miles and it has just done 119k miles now.

The only thing that puzzles me is the fact that the gears will only change smooth if the car is in motion, so as stated above, if I'm about to approach to a stop and want to shift from second to first, it does this like knife on butter. If however, the car stops and is put in neutral, then I find it hard to shift to 1st. Again, if the car is switched off, then I can move to any gear without an issue, as soon as the car is turned on, the struggle begins.

[j mitchell]

Hi if pumping the pedal improves the situation i would suggest you should bleed the system completely therefore ridding the system of all the old fluid and possible air locks before you purchase the master/slave cyl.seals .

[Sineda]

Sorry for not coming back - better late than never. The issue was resolved with a new clutch. I took the car to a Toyota specialist and they checked the space cylinders which were in tip top condition.