'91 4Runner V6 4x4 with 305,000 miles.
Recently I heard and felt a really loud 'Pop' from the clutch pedal while shifting gears. Not really sure how better to describe it.
Anyhow, ever since then it's been getting harder and harder to shift gears and my clutch pedal is creaking. I have to push the clutch all the way to the floor and I'm still not getting full disengagement.
Cannot get it into reverse without grinding. If I try to start the truck while it is in reverse I get nothing. Acts as if I'm not even pushing the clutch pedal at all. Can't even start it using the clutch bypass switch when it is in reverse.
It starts fine when in any other gear.
It is not low on fluid. No leaks. No signs of a fading or failing clutch prior to the 'Pop'.
I examined the pedal and could not find anything that looks cracked or broken.
I did notice that the button/switch at the bottom of the pedal swing was not getting fully depressed. I readjusted it but this did not make a difference.
I also noticed a button/switch at the top of the pedal swing that gets depressed when the clutch pedal is released but it appears to be operating normally. What exactly do those two switches do anyway?
I know this isn't an absolute test but I am able to put it into 3rd gear from a stop on level surface and take off with no problems.

Any help would be appreciated.

Sounds like a clutch MC from here. There's a chitload of little seals and crap in there, so you don't necessarily lose fluid when the MC goes south, the fluid can just blow by the seals internally and go nowhere.

The good news is, a rebuilt MC is pretty cheap and the rebuild kits are even cheaper. It's about an hour job to R&R the assembly, bleed and adjust, about an hour longer to do a rebuild.

Good luck, hope this helped in some way.

Mike

Toyota has the rebuild kit for $31.57. Will I need to 'Bench-Bleed' it after the rebuild? If so, how exactly do I do it? I've never done a MC rebuild before but I'm a fairly good mechanic and I can usually figure things out pretty easily.

Also, what is the purpose of the two button/switches that the clutch pedal hits?

Thanks,

it could be the master cylinder, but if you heard a popping sound, it could also be the plastic brace that holds the pedal. if that broke, then there's no pivot point, so you wouldn't even be pushing on the master cylinder. it's worth checking out.

One switch is so you won't start the truck when it is in gear. I am not sure about the other one, though

I had already inspected the bracket holding the clutch and didn't see any broken parts, but after reading mike d's post I decided to investigate further.
It's not the plastic brace that's busted; it's the base plate on the firewall that all of the pedal brackets mount to that's broken.
Nice fat crack right next to the clutch MC push rod.
Here are some pics:
CRACKED1
CRACKED2

Anyone got a part number on that?
How difficult is it going to be to replace?
I still would like to get a defenite answer on what the two buttons the clutch pedal hits are for???

Thanks.

I had a similar problem on a 1981 toyota 22r 5 speed. In my case it was a broken/damaged clutch preasure plate.

Clutch Pedal Bracket... The consensus seems to be weld it as the new part is pricey. There is a brace available IIRC as well. My friends's '89 truck cracked the mount, we welded that sucker up good, no probs.

Mike

Unfortunately I do not have ready access to a welder. Anyone have a part number for that bracket?

Does anyone know what the two clutch pedal buttons are for?

Thanks,