'92 Toyota Truck---Won't shift while running

[HuskerSam]

I've got a 5 speed 2WD pick-up 22RE

It won't start unless I get underneath and manually depress the slave cylinder, or push in the button (clutch bypass?) that sits in front of the clutch pedal. Once the truck is started then I can not shift at all. When it was going bad it got progressively harder to shift reverse being the worst..grinding, hard shifting etc.
So far I have replaced the slave and master cylinders, and the pressure plate, clutch and no change to the situation.
The actuating arm that goes directly into the transmission has about 3/8+ motion when working the clutch. The hydraulic lines have been blead and the pedal has pressure when depressed. The truck shifts fine when not running.
This one has really got me stumped, as well as any of my buddies that have come by to offer their two cents. Any thoughts would help and beleive me the simple solutions are the ones that are most likely being overlooked.

Thanks,

Sam

[GregoryM]

Sam: It doesn't seem to be getting enough travel on the linkage. Inspect the pedal and its mounting bracket for wear or possible cracking/bending, etc. Be sure that the system is completely bled. Some times they can be a real bear to get all the air out. You don't mention changing the throwout bearing, is it good? There is an adjustment on the pushrod between the pedal and the master cylinder. You can try increasing the length. I know the clutch is already installed but, I always check the splines on the input to make sure the disc slides back and forth without any drag. If needed, you can touch up the splines in the clutch disc with a small grinding stone. That will help your shifts to be clean and free of grinding. Hope that helps. Good luck.

[HuskerSam]

Greg:

Thanks for the tips. Very much appreciated.


BTW, I did change the throwout bearing.




Thanks,
Sam

[Mr Tode]

Sam,

I'm having a similar issue with my 20R truck, and I still haven't tracked down the culprit. Though my problem doesn't seem as severe as yours.

The only thing that I haven't changed on my truck is the flex line that connects the master to the slave. Not sure if your 92 has that line--on my truck, it's a hard line right out of the master, then there's a section of flex line at the base of the firewall, then hard line the rest of the way to the slave.

I wouldn't say the flex line is a particularly likely candidate, but it might be another variable to inspect.