Grabbing/resistence in clutch mechanism

SilverTTSR544 · Post by **SilverTTSR544** » Sat Mar 26, 2005 1:58 pm

I have an 86 4x4 Wagon with 151,000 miles. I'm only the second owner and bought it with 58,000 miles so I assume the clutch is original.

This clutch has always seemed different to me than any other car I've driven in that it has always engaged VERY close to the floor. It has always worked fine, it just seemed odd. Is that typical for these cars?

In any event, in the last few weeks a problem has developed. When I start to let out the clutch while waiting at a stop light, there's some drag, as if there's some friction or something resisting a bit, so that its difficult to smoothly let out the pedal and engage the tranny. I don't think the problem is in the pedal or the cable because it seems perfectly smooth when I push it in/out with the engine off -- it only seems sticky with the entine on. I feel the problem in other gears but its mostly a problem engaging first gear from a dead stop. The clutch disc itself is not slipping.

Anyone have suggestions on for trying to solve this problem without dropping the tranny? I looked at the forum on replacing a clutch, pulling engines vs. pulling the tranny, etc. and its beyond my abilities/time right now so I'd love to find a shortcut.

If there's no shortcut, I'll have my mechanic do a clutch job. I note from the other forum that people suggest NAPA parts or Toyota parts for this job, and they also suggest changing the crackcase seal at the same time. Anything else to keep in mind with a job like this?

takza · Post by **takza** » Sat Mar 26, 2005 3:33 pm

There is a sector & pawl mechanism at the clutch pedal...it's fairly easy to adjust it so you have more pedal play.

I adjusted mine way out so that it caught less than 6 teeth...maybe 4 (due to unrelated shifting probems at the shifter) and it's been doing fine for the last 30K miles. My clutch pedal is quite a bit higher than the brake pedal at rest.

It's supposed to self-adjust...but I'd try anyway.

You also could have throwout bearing or clutch issues....stretched cable?

clbolt · Post by **clbolt** » Sat Mar 26, 2005 4:27 pm

takza wrote: There is a sector & pawl mechanism at the clutch pedal...it's fairly easy to adjust it so you have more pedal play.

Yep, adjusting the stop on the clutch pedal just a couple of turns can make a noticeable difference on the engagement of the clutch. The Tercel self-adjuster system is good, but not flawless, and as old as these cars are, they do need a little tweaking from time to time.

BTW, I took the 86 to Wal-Mart in December for a new battery (free warranty replacement). After he was done, the tech (not an ignorant guy), commented that the clutch slave cylinder needed adjustment. I pointed out that it was a cable setup, and he was surprised. The Tercel system does have good feel for a cable.

Gasoline Fumes · Post by **Gasoline Fumes** » Sat Mar 26, 2005 10:21 pm

clbolt wrote: The Tercel system does have good feel for a cable.

I thought all cable systems had good feel. :huh:
To me, a hydraulic clutch feels like I'm stepping on a wet sponge.

clbolt · Post by **clbolt** » Sun Mar 27, 2005 6:22 am

Our VW Cabriolet has never had good feel. New cables don't really help, and they only last a year or so before they're unbearable. Almost every car I've ever owned with a cable setup gives some indication of the cable (roughness somewhere in the travel) except my Tercels.

hornett22 · Post by **hornett22** » Sun Mar 27, 2005 11:39 am

vw has been using a self adjusting cable for years.it is a piece of crap.i have had some luck replacing the rubber piece at the transmission end of the cable with a thinner one.this seems to help.vw dealers sell different thicknesses.get the thinnest one available.

SilverTTSR544 · Post by **SilverTTSR544** » Mon Mar 28, 2005 12:18 am

Good to hear about the pedal mechanism adjustment. I'll give it a try and report back.

SilverTTSR544 · Post by **SilverTTSR544** » Mon Mar 28, 2005 1:04 am

Well, I went out and made the simple, quick pedal adjustment to the point where the pedal was slightly higher than the brake pedal at rest. It had been lower, something I never really noticed before. I then took the car around the block and the clutch seems to be working MUCH better.

Thanks for the tip Takza! Guess I just needed a little more pedal travel.