Clutch cylinder removal & repiar for toyota master ace surf 91 import

spongy clutch feeling normally is Hydraulic.If you get under the vehicle -after you take all the safety precautions first- get close to the gearbox housing ( it is where the Engine joined the housing) and on the side of that housing you will see a flexible hose covering the clutch bearing fork and a clutch slave cylinder attached to that fork. Possible to see that is wet of clutch fluid (if is that the fault ). Also check if the clutch master cylinder is the fault and the clutch fluid reservoir if it has sufficient fluid in.

you bleed the same as you would bleeding brakes. you just won`t get the hard pedal like with brakes but you should feel resistance and no air coming out of system when you open the bleeder screw on the slave cylinder. make sure the reservoir does not get empty or you won`t get the air out of system.

Yes they are the same . Check that the master cylinder is operational as a slipping clutch can be a blocked compensating port not allowing the fluid to drain back to the reservoir and holding the pressure on the clutch release.

remove line from the side of clutch master cylinder two bolts or nuts on firewall inside vehicle is a pin on the upper side of clutch remove and pull old unit out bench bleed new master by filling and pressing in on the piston of the master cylinder. if you dont have a hose fitting dont bench bleed bleed it in vehicle( this method takes longer) install back in vehicle and hook it all back up torque bolts to 25 ft lbs then bleed the slve cylinder from under vehicle near back of motor just like bleeding brakes pump up hold and release the line pressure by opening valve on slave cylinder.

There should be a small cup size reservoir on the fender strut tower. Looks like thing in upper right corner of below picture. What usually happens to hydraulic clutches when they draw air, it the slave cylinder on the side of the transmission leaks and must be replaced. The system can then be bled of air and proper clutch operation restored. It would be difficult to restore clutch operation just by refilling the reservoir, especially with such a small reservoir. If it is necessary to get the car moving to get it repaired (slave cylinder replacement is a big job on this car, as the transmission must be removed), one could bleed the system with the bad slave cylinder and then drive a short distance. The clutch will likely fail again after about 100 or so cycles of the pedal. I will paste the bleed instructions below. These require someone to get under the car to open the slave bleeder. If you have more questions, please let me know.

Bleeding The Hydraulic System

Note: brake fluid is corrosive--please wipe any spilled fluid from painted or metal surfaces.
Manual Bleeding

1. Fill the clutch reservoir with brake fluid. Check the reservoir level frequently and add fluid as needed.
2. Connect one end of a vinyl tube to the bleeder plug on the slave cylinder and submerge the other end into a clear container half-filled with clean brake fluid.
3. Slowly pump the clutch pedal 10-15 times without bring the pedal the full way up.
4. Repeat Steps 2 and 3 until all of the air bubbles are removed from the system.
5. Tighten the bleeder screw to 62 inch lbs. (7 Nm).
6. Refill the master cylinder to the proper level.

Replacing the clutch slave cylinder:

Removal & Installation Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

1. Disconnect the clutch master cylinder line from the transaxle by removing the C-clip.
2. Remove the transaxle.
3. Remove the clutch actuator cylinder bolts from the transaxle.
4. Remove the clutch actuator cylinder.

To install:


NOTE Excessive amounts of lubricant on the input shaft splines can contaminate the clutch disc and cause clutch shudder.

1. Lightly lubricate the inside diameter of the bearing with input shaft lubricant P/N 21005995 or equivalent.
2. Install the clutch actuator cylinder (1) to the transaxle.
3. Install the clutch actuator cylinder bolts.
4. Tighten the bolts to 89 inch lbs. (10 Nm).
5. Install the transaxle.
6. Connect the clutch master cylinder line to the transaxle by pushing it in until it seats.
7. Bleed the clutch hydraulic system.

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

1. Disconnect the clutch master cylinder line from the transaxle by removing the C-clip.
2. Remove the transaxle.
3. Remove the clutch actuator cylinder bolts from the transaxle.
4. Remove the clutch actuator cylinder.

To install:


NOTE Excessive amounts of lubricant on the input shaft splines can contaminate the clutch disc and cause clutch shudder.

1. Lightly lubricate the inside diameter of the bearing with input shaft lubricant P/N 21005995 or equivalent.
2. Install the clutch actuator cylinder (1) to the transaxle.
3. Install the clutch actuator cylinder bolts.
4. Tighten the bolts to 89 inch lbs. (10 Nm).
5. Install the transaxle.
6. Connect the clutch master cylinder line to the transaxle by pushing it in until it seats.
7. Bleed the clutch hydraulic system.

Master or slave cylinder is possibly faulty and/or leaking

Does the clutch pedal feel any harder or softer than ussual?it could be the clutch and pressure plate are worn or hopefully just that the master or slave cylinder is leaking.The master cylinder is under the hood opposite side to the steering wheel and slave cylinder at the gearbox

There is a small "master cylinder", forthe clutch, located on the driver side of the engine compartment, below the master cylinder.

dude under truck left hand sideof tranny, is your clutch slave cylinder, remove the hydraulic line, the two mount bolts. replace the slave cylndr. you got clutch !!!!

ps i dont recall there being a bleed valve. it should bleed by gravity


james ray

You seem to have a bad or weak pressure plate. Even if its relatively new it may be defective. As far as help to remove the gearbos our its alot of work and its very heavy. I would need a transmisson jack to hold the box. reove all the bolts arount the bell housing the starter and lines to slave cylinder. You should be able to wiggle the box out. To re-install you need a clutch alignment tool.
ps. USE OEM PARTS ONLY (dealer parts) TO REPLACE, TOO MUCH WORK FOR AFTER MARKET PARTS. Good Luck