Clutch Master Cylinder (For Rhd) Installation

except 1GD-FTV:

1. Install a new gasket.
   

for 1GD-FTV:

1. Install a new gasket and clutch master cylinder bracket.
   

Install the clutch master cylinder with the 2 nuts.

Torque:

14 N*m{145 kgf*cm, 10 ft.*lbf}

Apply MP grease to the contact surfaces of the pin and clevis bush.

Connect the clevis to the clutch pedal with the pin.

Install a new clip to the pin.

Using a union nut wrench, connect the flexible hose tube.

Torque:

14 N*m{145 kgf*cm, 10 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (LandCruiser RM000003YMD00TX.html).

Install the clutch master cylinder heat insulator with the 2 nuts.

Torque:

15 N*m{50 kgf*cm, 43 ft.*lbf}

Fill the reservoir with brake fluid.

Brake fluid:

SAE J1703 or FMVSS No. 116 DOT 3

NOTICE:

for Hydraulic Brake Booster:

As brake fluid may overflow when fluid is released from the brake actuator, do not leave the brake fluid can in the reservoir filler opening when adding brake fluid.

Remove the bleeder plug cap of the release cylinder.

Connect a vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

Repeat the previous 2 steps until all the air in the fluid is completely bled.

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled from the clutch line.

Check the fluid level.
If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.

Brake fluid:

SAE J1703 or FMVSS No. 116 DOT 3

Fold back the floor carpet.

Check that the pedal height is correct.

Pedal height from floor:

Engine	Specified Condition
2TR-FE 5L-E	158.5 to 168.5 mm (6.25 to 6.63 in.)
1GR-FE 1GD-FTV 1KD-FTV	171.4 to 181.4 mm (6.75 to 7.14 in.)

Adjust the pedal height.

1. w/ Cruise Control System:
   Loosen the lock nut and turn the clutch switch until the height is correct. Tighten the lock nut.
   

   Torque:

   16 N*m{160 kgf*cm, 12 ft.*lbf}

2. w/o Cruise Control System:
   Loosen the lock nut and turn the clutch pedal stopper bolt until the height is correct. Tighten the lock nut.
   

   Torque:

   26 N*m{260 kgf*cm, 19 ft.*lbf}

Check the pedal free play and push rod play.

HINT:

Pay close attention to the change in resistance to distinguish between pedal free play and push rod play while performing the inspection.

1. Depress the clutch pedal until resistance is felt.
   

2. Measure the distance between the pedal's released position and the position in the previous step.
   

   Pedal free play:

   5.0 to 15.0 mm (0.197 to 0.591 in.)
   

3. Release the pedal. Using your finger, gently press the pedal until resistance increases slightly.
   

4. Measure the distance between the pedal's released position and the position in the previous step.
   

   Push rod play at pedal top:

   1.0 to 5.0 mm (0.0394 to 0.197 in.)
   

Adjust the pedal free play and push rod play.

HINT:

The push rod play can be adjusted by changing the length of the push rod. Pedal free play changes together with push rod play.

1. Loosen the lock nut and turn the push rod until the pedal free play and push rod play are within the specified ranges.
   

   NOTICE:

   If pedal free play and push rod play are not within the standard range even after adjustment, inspect the related parts.

2. Tighten the lock nut.
   

   Torque:

   12 N*m{120 kgf*cm, 9 ft.*lbf}

3. After adjusting the pedal free play and push rod play, check the pedal height.
   

Check the clutch release point.

1. Pull the parking brake lever and use wheel chocks to stabilize the vehicle.
   

2. Start the engine and run it at idle.
   

3. Without depressing the clutch pedal, slowly move the shift lever to R until the gears contact.
   

4. Gently depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.
   

   Standard distance:

   25 mm (0.984 in.) or more
   

   If the result is not as specified, perform the following procedures.
   
   1. Check pedal height.
      
   1. Check push rod play and pedal free play.
      
   1. Bleed air from clutch line.
      
   1. Check clutch cover and disc.