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  • "MariusTK" started this thread

Posts: 1

Date of registration: Dec 4th 2017

Location: Centurion

Car: 2010 Fortuner 30.D4D

Level: 5 [?]

Experience: 104

Next Level: 173

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Monday, December 4th 2017, 10:31am

Clutch Problems.....HELP PLEASE

Hi Guys, Sorry for the long Message... but please help

I have bought a 2010 Fortuner 30.D4D Manual 4x2 last year, I just Love the Fortuner, But.....

In February, I felt the clutch were a bit spongy sometimes,
then the clutch disappear and the pedal is on the floor. If you press slowly on
the clutch then the clutch will fade away without engaging. if you Press the clutch normal / fast then there is clutch....I also notice that
there was NO brake fluid leaking on the Master/Slave cylinder. I did read
multiple forums regarding this and all indicate that this was a problem with
the Master Cylinder, so I went and bought both Master and Slave Cylinders.

After this was replaced by myself and the issue went away. But
the issue returned after 2 months. Same problem, so I returned the Master
Cylinder and got a new one.

2 months later the problem returned… I then removed the “accumulator”
thinking that the Master Cylinder can not be Faulty again. Yet 2months later
the issues returned again.

I am out of ideas and need some advice to fix this
correctly. I do not want to spend a lot of money on “fixing” this and still
have the problem..

What I know now:
- Master Cylinder can Not be Faulty, replace it 3
- The System is Clean and there is no other Mechanical
devices between the Master and Slave. 1 to 1
- There is no leaks.

Might be:
- Still Air in the System?
- Using Dot4 and not Dot3?



Posts: 21

Date of registration: Nov 15th 2015

Location: Nelspruit

Occupation: Eng

Car: 2008 D-4D 2x4

Level: 19 [?]

Experience: 17,921

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Monday, December 4th 2017, 1:38pm

Yes Marius,

How many km's on your Fortuner?

It seems the pressure plate is the problem. The springs gets harder over time, then the pressure gets too high, and the master cylinder seal pop. If the pedal collapses and you pull it back, the seal reseat for a while and then the problem starts again. Mine and a mate of mine's did the same, best is to replace the clutch ASAP because if the seal collapse entirely you won't have any clutch at all (happened to me). Apparently the LUK clutches are prone to do this, I've replaced with an Aisin clutch (both are apparently OEM's for Toyota).

I also replaced the master cylinder, seemed OK for a month or 2 and then the new (pirate) one did the same. When I had the clutch replaced I had to replace the master cylinder again (replaced with Toyota one), after the clutch was replaced one could see the brake fluid swirling in the reservoir which pointed to seal collapsed. There weren't any leaks, the master cylinder was bypassing at that stage.

The cost of the clutch kit was R 3K, another R 3.5 K for labour, another R 1.5 K for Toyota master cylinder. My mate found somebody who could replace the seal, I don't know how he does it because it looks like a sealed unit...

Not a cheap exercise but hopefully it fixes the problem.

My 2c worth...



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