Outer Limits 4x4 Board

hey guys another question had a qucik search but looks like heaps has been deleted

i got a LN106 Hilux. diesle 5 speed manual. now my problem is the clutch wont fully dis engage at times.

just happened over night (litterally moved it 1 day and nothing)

it happens when you put the clutch in(its all good select all gears at idle no problem). then when you release the clutch to the friction point(is really touch all of a sudden to) it wont release. wont dis engage until you start moving and grab another gear or neautral. but when driving its the same issue if you start to relase the clutch then clutch in again to slow down (coasting) it wont do that and still wants to drive

i replaced the clucth slave thinking it was bypassig internally but that didnt fix the issue,. i only replaced the clucth master in january but i had water and mess in it a few times and flushed it out(so i believe i did it properly) the clutch is lucky to be 10.000ks old

some1 mentioned it might be the rubber flexi line between the hardline and slave cylinder. but cant find 1 so i gotta wait till friday for it to turn up

has any1 had this issue befor? i trying to find anything it might be befor i have to drop the gearbox as i really CFB'd and dont really have the time as car has to be running and working properly for a 4wd event in a week and a half

Is the clutch fork moving freely ? could the mud/oil/dust/swamp weed etc. have got into the bellhousing causing the throwout bearing to bind on the gearbox snout ? Was the snount lubed when the gearbox/throw out installed ?

My .50 cents

Is the clutch pedal moving through its normal travel? If the pedal is going to the floor and the clutch will not release I would suspect a hydraulic problem. Have you tried bleeding, does pumping the pedal make any difference? The sudden grab you describe also makes me think hydraulics. Even a near new master cylinder could have a faulty or damaged seal or have picked up some water or grit. PLEASE post a result so we can all learn from this forum.

the clutch pedal goes to the floor and works normally at idle with no load. once i release the clutch a little it grabbes straight away(not fully engaged but to engaged to shift) and then to disengage the slected gear i have to turn the car off or drive so i can pop it out since its loaded up.

i might try a new master as well just for cheap insurance. the clutch doesnt seem to be leaking back when no load but i m not game to jump under and have some1 in the drivers seat and release the clutch a little and observe incase somethin bad happens and i get squashed

well just had a mate help me. i cant push the clutch fork by hand.(i guess that means the fingers are still pushed out and they are still good)

the driver put the xca in gear and let the clutch off till priction point and then when he tried to clucth in to dis engage the clutch the fork didnt move and the slave cylinder didnt move. so from what i can tell its bypassing within the line or master cylinder) because the throwout bearing was moving smoothly when no load is applied and the plutch pedal still went to the floor and no fluid traveled to the slave cylinder and the pedal doesnt get any harder when this happens/ it actually goes soft and spongy.

does my theory sound correct? please tell me any other thoughts

i have bled it 3 or 4 times and i know for sure there is no air in the system

Well after replacing the flexi line and that not fixing the issue I replaced the master cylinder and bam fixed the issue. So excited as I really didn't want to drop the box cheers for the help guys