Toyota Tacoma

Clutch Pedal Bushing Replacement

Vehicle Information: 1996 Toyota Tacoma, manual transmission, 4WD 3.4L V6, 74,000 miles
These are basic instructions on how to replace clutch pedal turnover bushing. THANKS go out to Mickey Ingles for helping me with this repair!
If you have any questions about this write-up visit: www.lieblweb.com and e-mail us!
Use this information AT YOUR OWN RISK!
**NOTE** It's not uncommon to replace this bushing once every year depending on your driving. I've replaced mine twice so far.

Troubleshooting: On Toyota Tacoma trucks equipped with manual transmissions, a squeak or grind is often heard when pushing down on the clutch pedal. This squeak or grind can also be confused with another clutch related problem - so please make sure you are performing the proper repair for the problem you are encountering. Take time to read the information below- and you should be able to take a look at your current clutch pedal turnover bushing and make a decision if it needs to be replaced.

Parts Needed & Other Information: Toyota Part #90389-05017 .  Please make note - this part is for the vehicle listed above. We ordered it from Conicelli Toyota www.partznet.com. Make sure when ordering any parts that they are specific to YOUR application.

Tools Needed: 12mm socket with extensions, workbench equipped with a VICE, needle nose pliers may be needed, safety glasses recommended and other tools may be necessary.

Description & Location:
The clutch pedal is mounted on a large bracket assembly. The entire bracket assembly will need to be removed to perform the final repairs.

Step 1:
Remove the cotter pin from the clutch shaft roll pin as seen in the picture. After removing the cotter pin, remove the roll pin. This will free the clutch shaft from the pedal assembly.

cotter

Step 2:
Unplug both electronic clutch pedal sensing devices - as seen in the picture.

image
Step 3:
Remove the top bolt (as seen in the picture) using a 12mm socket with extension. 

bolt
Step 4:
Open up your hood and look in the upper right corner. This is your clutch master cylinder where the hydraulic fluid is stored.  Remove the 2 nuts as seen here.  The master cylinder will remain in it's position even after you remove it's mounting nuts/studs. 

boltshood
Step 5:
Go back inside the cab of the truck and gently pull the entire clutch pedal assembly. Be careful of the wires and other parts in the area.

assembly
Step 6:
You'll want to secure the Clutch assembly in a vice by clamping on the pedal.  BE CAREFUL when handling this assembly. The spring has a lot of potential force.  The pedal can move positions and if you're not careful, you could pinch yourself unexpectedly. 

The new bushing fits in between the spring and the clutch pivot arm (as seen in the picture). It is a horse-shoe shaped part that will snap into place. 

As you can see here, the original bushing is completely gone and the forces have began to wear away at the metal. 

This is a picture of what the new bushing looks like. It is very very small!

closeup
Bushing:
Please pardon this blurry picture - this is what a brand new clutch pedal turnover bushing looks like. It's very tiny.
bushing
Step 7:
CAUTION!  Wear safety glasses!!
You'll want to put the central spring arm (where the bushing is placed)  at its lowest position.  This will help remove some of the spring tension.  Remember - the spring has a lot of stored energy (forces).  If you are not careful, it can snap and cause injury! 

By taking a long screwdriver or some type of prying device, pry one end of the spring out of its spring seats. You should be able to remove the other side rather easily now that the spring is no longer under tension. 

TAKE NOTE! 
Take notice to the exact position of the spring when it is removed.  You will need to install it in the exact way as it came off. 

spring
Step 8 :
Install New Bushing: 
Now that you've got that spring out of the way, you can easily install the new bushing.  I decided to add some grease to the bushing before installation. 

I also added some grease to the spring seats.

Now - the fun part begins!

nospring
Step 9 :
Remember to install the spring in the exact position it was when you removed it.

First, insert one side of the spring into its spring seat.  Then, insert the center spring piece into the new bushing. This may take a little bit of muscle and some prying.

Finally, with some prying - try to compress the spring enough to get the spring into the other spring seat. 

Again, be very careful with the spring. You will be applying pressure (adding tension) to the spring in order to finish the installation.  If you slip just a little, that spring tension will let go and could cause injury. 

done