Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

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Old 12 Nov 2010, 02:43 pm   #1 (permalink)
Jack
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Default Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

After 220k miles, my 1996 4WD 2.7L Tacoma developed an intermittent squeak
when the clutch is depressed, and sometimes only upon release. There is no
obvious connection to weather, etc. I first noticed it on a hilly, low-
speed dirt road this summer. It will go away for hours or even days, then
return, mostly during frequent shifting.

This is a separate issue from the other common squeak caused by lack of
grease on the pivot arm inside the bell housing.

According to TSB TC005-99, on 4-cylinder models you're supposed to replace
the entire Clutch Pedal Support Bracket [RZN] (formerly P/N 55107-35040)
with the redesigned bracket (P/N 55107-04010). But it doesn't explain
exactly what's causing the squeak, which sounds like rubber on metal (or
wet rubber). At one point I thought it was my shoe squeaking on the pedal;
a similar sound.

I asked a dealer mechanic the exact reason for the squeak but he only knew
of the V6 issue, which involves replacing the U-bushing on the torsion
spring (the TSB recommends NO grease for the V6 or the L4). The 4-cyl.
apparently has a different pedal mechanism but I'm not sure how it differs.

This issue appears on Tacoma web forums but nobody seems to understand the
true source of the squeak. You read the usual assumptions about using
grease (NOT recommended in the TSB) or tightening the pushrod nuts, which
never quite fixes the problem.

I don't understand why you'd have to replace the entire Clutch Pedal
Support Bracket (for $100) after it's worked w/o noise for 220k miles. Does
the bracket get warped over time? What exactly is causing the noise?

Thanks for any technical info. - Jack -
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Old 13 Nov 2010, 02:15 am   #2 (permalink)
Rhaspun
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Default Re: Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

On Nov 12, 12:43*pm, Jack <jack...@site.com> wrote:
> After 220k miles, my 1996 4WD 2.7L Tacoma developed an intermittent squeak
> when the clutch is depressed, and sometimes only upon release. There is no
> obvious connection to weather, etc. I first noticed it on a hilly, low-
> speed dirt road this summer. It will go away for hours or even days, then
> return, mostly during frequent shifting.
>
> This is a separate issue from the other common squeak caused by lack of
> grease on the pivot arm inside the bell housing.
>
> According to TSB TC005-99, on 4-cylinder models you're supposed to replace
> the entire Clutch Pedal Support Bracket [RZN] (formerly P/N 55107-35040)
> with the redesigned bracket (P/N 55107-04010). But it doesn't explain
> exactly what's causing the squeak, which sounds like rubber on metal (or
> wet rubber). At one point I thought it was my shoe squeaking on the pedal;
> a similar sound.
>
> I asked a dealer mechanic the exact reason for the squeak but he only knew
> of the V6 issue, which involves replacing the U-bushing on the torsion
> spring (the TSB recommends NO grease for the V6 or the L4). The 4-cyl.
> apparently has a different pedal mechanism but I'm not sure how it differs.
>
> This issue appears on Tacoma web forums but nobody seems to understand the
> true source of the squeak. You read the usual assumptions about using
> grease (NOT recommended in the TSB) or tightening the pushrod nuts, which
> never quite fixes the problem.
>
> I don't understand why you'd have to replace the entire Clutch Pedal
> Support Bracket (for $100) after it's worked w/o noise for 220k miles. Does
> the bracket get warped over time? What exactly is causing the noise?
>
> Thanks for any technical info. - Jack -


Check out the spring that pulls on the clutch pedal.
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Old 13 Nov 2010, 05:52 pm   #3 (permalink)
Jack
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Default Re: Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

Rhaspun <rhaspun@gmail.com> wrote in
news:0c8beb80-6404-4a2a-befe-7c65ae031536@a9g2000pro.googlegroups.com:

> Check out the spring that pulls on the clutch pedal.


And what exactly about the spring (which I'm well aware of) would be
causing the noise?

Jack
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Old 13 Nov 2010, 08:01 pm   #4 (permalink)
JMc
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Default Re: Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

My 97 4Runner developed a clutch pedal squeak which I discovered to be the
result of deterioration and disintegration of a small nylon bushing in the
clutch pedal linkage. I tried to purchase the bushing but had it explained
to me that it was not a replaceable part, that I needed to replace the
entire linkage assembly. That was at about 150k miles. I went home and
tried several different lubricants and found that white lithium grease in an
aerosol can worked best and lasted longest. So, for the next 75k miles I
turned upside down and sprayed the linkage ever 4-6 months or when it
started the annoying squeak again. Just traded that 4Runner in on a 2010
Tacoma this past spring. I'll have to take a flashlight out and see if the
same whit nylon bushing is still in the pedal design. Maybe I should begin
a program of pm on it.

"Jack" <jack945@site.com> wrote in message
news:Iomdnf-25c5uO0DRnZ2dnUVZ_sSdnZ2d@wavecable.com...
> After 220k miles, my 1996 4WD 2.7L Tacoma developed an intermittent squeak
> when the clutch is depressed, and sometimes only upon release. There is no
> obvious connection to weather, etc. I first noticed it on a hilly, low-
> speed dirt road this summer. It will go away for hours or even days, then
> return, mostly during frequent shifting.
>
> This is a separate issue from the other common squeak caused by lack of
> grease on the pivot arm inside the bell housing.
>
> According to TSB TC005-99, on 4-cylinder models you're supposed to replace
> the entire Clutch Pedal Support Bracket [RZN] (formerly P/N 55107-35040)
> with the redesigned bracket (P/N 55107-04010). But it doesn't explain
> exactly what's causing the squeak, which sounds like rubber on metal (or
> wet rubber). At one point I thought it was my shoe squeaking on the pedal;
> a similar sound.
>
> I asked a dealer mechanic the exact reason for the squeak but he only knew
> of the V6 issue, which involves replacing the U-bushing on the torsion
> spring (the TSB recommends NO grease for the V6 or the L4). The 4-cyl.
> apparently has a different pedal mechanism but I'm not sure how it
> differs.
>
> This issue appears on Tacoma web forums but nobody seems to understand the
> true source of the squeak. You read the usual assumptions about using
> grease (NOT recommended in the TSB) or tightening the pushrod nuts, which
> never quite fixes the problem.
>
> I don't understand why you'd have to replace the entire Clutch Pedal
> Support Bracket (for $100) after it's worked w/o noise for 220k miles.
> Does
> the bracket get warped over time? What exactly is causing the noise?
>
> Thanks for any technical info. - Jack -


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Old 14 Nov 2010, 01:36 pm   #5 (permalink)
Jack
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Default Re: Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

"JMc" <mcdonaldjc@verizon.net> wrote in
news:ibnfua$qbv$1@news.eternal-september.org:

> My 97 4Runner developed a clutch pedal squeak which I discovered to be
> the result of deterioration and disintegration of a small nylon
> bushing in the clutch pedal linkage. I tried to purchase the bushing
> but had it explained to me that it was not a replaceable part, that I
> needed to replace the entire linkage assembly. That was at about 150k
> miles. I went home and tried several different lubricants and found
> that white lithium grease in an aerosol can worked best and lasted
> longest. So, for the next 75k miles I turned upside down and sprayed
> the linkage ever 4-6 months or when it started the annoying squeak
> again. Just traded that 4Runner in on a 2010 Tacoma this past spring.
> I'll have to take a flashlight out and see if the same whit nylon
> bushing is still in the pedal design. Maybe I should begin a program
> of pm on it.


A dealer mechanic mentioned that bushing (and recommended full
replacement), but TSB TC005-99 says that applies to the V6, not the 4-
cylinder models. It doesn't explain why that is, since they both seem to
have a similar bushing on the torsion spring. I haven't crawled under the
dash and studied my pedal yet, but my 95-97 factory manual only shows one
style of clutch pedal.

My original question was about why they recommend replacing the entire
clutch pedal support bracket ($100). They don't recommend grease for
either model, so lube seems like a temporary fix - as you've noticed. I
haven't tried lube, but may end up doing so.

I mainly want to know the reason for the 4-cyl. bracket redesign and
whether that relates to the bushing at all.

To make it clearer, here is TSB TC005-99, with diagrams:

http://tinyurl.com/37wmf5p (view at "original" size)

This newsgroup used to get postings from dealer mechanics who had done
actual TSB repairs. Is anyone still around?

Jack
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Old 14 Nov 2010, 07:59 pm   #6 (permalink)
JMc
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Default Re: Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)



"Jack" <jack945@site.com> wrote in message
news:0bydnTTrgsGtp33RnZ2dnUVZ_uadnZ2d@wavecable.co m...
> "JMc" <mcdonaldjc@verizon.net> wrote in
> news:ibnfua$qbv$1@news.eternal-september.org:
>
>> My 97 4Runner developed a clutch pedal squeak which I discovered to be
>> the result of deterioration and disintegration of a small nylon
>> bushing in the clutch pedal linkage. I tried to purchase the bushing
>> but had it explained to me that it was not a replaceable part, that I
>> needed to replace the entire linkage assembly. That was at about 150k
>> miles. I went home and tried several different lubricants and found
>> that white lithium grease in an aerosol can worked best and lasted
>> longest. So, for the next 75k miles I turned upside down and sprayed
>> the linkage ever 4-6 months or when it started the annoying squeak
>> again. Just traded that 4Runner in on a 2010 Tacoma this past spring.
>> I'll have to take a flashlight out and see if the same whit nylon
>> bushing is still in the pedal design. Maybe I should begin a program
>> of pm on it.

>
> A dealer mechanic mentioned that bushing (and recommended full
> replacement), but TSB TC005-99 says that applies to the V6, not the 4-
> cylinder models. It doesn't explain why that is, since they both seem to
> have a similar bushing on the torsion spring. I haven't crawled under the
> dash and studied my pedal yet, but my 95-97 factory manual only shows one
> style of clutch pedal.
>
> My original question was about why they recommend replacing the entire
> clutch pedal support bracket ($100). They don't recommend grease for
> either model, so lube seems like a temporary fix - as you've noticed. I
> haven't tried lube, but may end up doing so.
>
> I mainly want to know the reason for the 4-cyl. bracket redesign and
> whether that relates to the bushing at all.
>
> To make it clearer, here is TSB TC005-99, with diagrams:
>
> http://tinyurl.com/37wmf5p (view at "original" size)
>
> This newsgroup used to get postings from dealer mechanics who had done
> actual TSB repairs. Is anyone still around?
>
> Jack


Very interesting, and thanks for posting the TSB. I know it was you who had
the question, and you ended up providing some additional insight to a puzzle
I wrestled for a couple years and several 10's of thousand miles. At this
point, I can absolutely confirm lubricant was only a temporary fix, and once
the bushing was damaged, it did get a little sloppy, but never enough to
make clutch action inoperable. I know quite a bit less about that era of
Tacoma, is it possible the 4cyl clutch was mechanical while the v6 was
hydraulic? Unfortunately, you are right, there is very little traffic here
in this news group any longer. Have you tried one or another of the Tacoma
World (http://www.tacomaworld.com/forum/) or Tacoma Nation forums. They at
least have plenty of traffic.

Good luck,
Jere

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Old 15 Nov 2010, 03:25 am   #7 (permalink)
Jack
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Default Re: Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

"JMc" <mcdonaldjc@verizon.net> wrote in
news:ibq46g$dj4$1@news.eternal-september.org:

>
>
> "Jack" <jack945@site.com> wrote in message
> news:0bydnTTrgsGtp33RnZ2dnUVZ_uadnZ2d@wavecable.co m...
>> "JMc" <mcdonaldjc@verizon.net> wrote in
>> news:ibnfua$qbv$1@news.eternal-september.org:
>>
>>> My 97 4Runner developed a clutch pedal squeak which I discovered to
>>> be the result of deterioration and disintegration of a small nylon
>>> bushing in the clutch pedal linkage. I tried to purchase the
>>> bushing but had it explained to me that it was not a replaceable
>>> part, that I needed to replace the entire linkage assembly. That
>>> was at about 150k miles. I went home and tried several different
>>> lubricants and found that white lithium grease in an aerosol can
>>> worked best and lasted longest. So, for the next 75k miles I turned
>>> upside down and sprayed the linkage ever 4-6 months or when it
>>> started the annoying squeak again. Just traded that 4Runner in on a
>>> 2010 Tacoma this past spring.
>>> I'll have to take a flashlight out and see if the same whit nylon
>>> bushing is still in the pedal design. Maybe I should begin a
>>> program of pm on it.

>>
>> A dealer mechanic mentioned that bushing (and recommended full
>> replacement), but TSB TC005-99 says that applies to the V6, not the
>> 4- cylinder models. It doesn't explain why that is, since they both
>> seem to have a similar bushing on the torsion spring. I haven't
>> crawled under the dash and studied my pedal yet, but my 95-97 factory
>> manual only shows one style of clutch pedal.
>>
>> My original question was about why they recommend replacing the
>> entire clutch pedal support bracket ($100). They don't recommend
>> grease for either model, so lube seems like a temporary fix - as
>> you've noticed. I haven't tried lube, but may end up doing so.
>>
>> I mainly want to know the reason for the 4-cyl. bracket redesign and
>> whether that relates to the bushing at all.
>>
>> To make it clearer, here is TSB TC005-99, with diagrams:
>>
>> http://tinyurl.com/37wmf5p (view at "original" size)
>>
>> This newsgroup used to get postings from dealer mechanics who had
>> done actual TSB repairs. Is anyone still around?
>>
>> Jack

>
> Very interesting, and thanks for posting the TSB. I know it was you
> who had the question, and you ended up providing some additional
> insight to a puzzle I wrestled for a couple years and several 10's of
> thousand miles. At this point, I can absolutely confirm lubricant was
> only a temporary fix, and once the bushing was damaged, it did get a
> little sloppy, but never enough to make clutch action inoperable. I
> know quite a bit less about that era of Tacoma, is it possible the
> 4cyl clutch was mechanical while the v6 was hydraulic? Unfortunately,
> you are right, there is very little traffic here in this news group
> any longer. Have you tried one or another of the Tacoma World
> (http://www.tacomaworld.com/forum/) or Tacoma Nation forums. They at
> least have plenty of traffic.
>
> Good luck,
> Jere


The clutches on all Tacomas (1995+) have been hydraulic.

I'm wondering if that TSB is poorly written and you're also supposed to
replace the bushing on the 4-cyl. along with the new bracket. I just
haven't studied mine yet (partly due to an injury). Seems odd that the
bushing is said to wear out much sooner than 220k miles on many trucks.

I know of TacomaWorld, etc, and have read a lot about the bushing problem.
General concept: http://www.lieblweb.com/clutchbushing.html (looks like a
hassle to just replace one small piece)

One guy made a custom bronze bushing to reduce failures, and to allow
grease to be used for more protection (grease on plastic isn't ideal).

I have also seen questionable advice about replacing the torsion spring
with a standard hardware store coil spring, which alters the pedal dynamics
that they engineered in.

The whole support bracket issue doesn't get much notice, but in reading
about some (T-100) bracket breakage problems, it may just be a stronger
design that holds its shape better. That leads me to wonder if one cause of
the squeak is not the bushing so much as the pedal alignment.

Too bad about this fading forum. Usenet as a whole has lost major ground to
the Web. But these posts get archived on various websites anyhow.

Jack
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Old 15 Nov 2010, 08:59 pm   #8 (permalink)
Jack
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Default Re: Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

For any & all concerned:

The 4-cyl. clutch pedal has a regular straight spring, not a torsion spring
like the V6. That's why the TSB makes no mention of a bushing for the 4-
cyl. trucks. The support bracket seems plenty sturdy and the reason for its
redesign is unclear.

Photo of 1996 4-cyl. clutch pedal: http://tinyurl.com/2dypvqb

It also remains unclear where the squeak originates in the 4-cyl. pedal
mechanism. It could be an entirely different origin and just coincidence
that both models end up squeaking after awhile.

Jack
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Old 16 Nov 2010, 10:02 am   #9 (permalink)
SnoBrdr
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Default Re: Clutch pedal squeak in 95-99 4-cyl. Tacoma (see TSB TC005-99)

Jack <jack945@site.com> wrote:

>For any & all concerned:
>
>The 4-cyl. clutch pedal has a regular straight spring, not a torsion spring
>like the V6. That's why the TSB makes no mention of a bushing for the 4-
>cyl. trucks. The support bracket seems plenty sturdy and the reason for its
>redesign is unclear.
>
>Photo of 1996 4-cyl. clutch pedal: http://tinyurl.com/2dypvqb
>
>It also remains unclear where the squeak originates in the 4-cyl. pedal
>mechanism. It could be an entirely different origin and just coincidence
>that both models end up squeaking after awhile.
>
>Jack


I have a 08, which also has a squeaky clutch pedal.
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