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Q: Regarding a 5spd manual transmission on 1994 Toyota T100

Here it is. My son has this truck, 1994 Toyota T100. To put it short the clutch was about to bite the dust. It would not hold on a slight incline and power loss.

So we installed a new clutch assembly. The friction disk was about to the top of the rivets.

Flywheel machined
New pilot bearing
New pressure plate
New clutch disk

All cleaned with brake cleaner and blown dry with compressed air.

Back together and it started, but would not hit a gear and only ground trying reverse.

Shut engine off, it goes through the gears.

The slave cylinder moves the throw out bearing arm about 5/8 an inch or so.

Does anyone have any idea what the heck is going on?

Also now the engine will not even turn over. The dash lights come on, the head lights and what nots, but the starter a no go and it is only about 3 months old. Did we miss something here?
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Hopefully you installed the clutch disc the right side out. Sounds like not releasing all the way which can happen if installed backwards. For the no crank prob check all connections at battery and especially at the starter which I assume you took off during the clutch work. Hopefully you did not damage the wiring attaching connect points at the solenoid.
The disk was installed the correct way, the shallow side of the realese spings on the flywheel side. The starter isn't that big of a deal, we can hear it pop kind of. I think the key left on for a while when we needed to turn the wheels due to the sway bar.

The pedal height from the foot side of the clutch pedal pad is about 6 inches. This is baffeling me. I am a former auto tech. After talking to my son I think the problem has basically compounded itself. He told me last night that what is happening now was only happening in first gear, the other four had to be kind of shoved into catch the gears.

From what I could figure the torque for the pressure plate is like 29 foot lbs I think. I hate Chilton manuals, but that is the only reference book we could find.

Thanks for the response. However still hoping for something as this can not be the only T100 to ever experience this sort of thing.
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