05 taco clutch horror story is 10x worse today

[dealingdawg]

So for the last couple years I've had two dealers in Austin tearing apart the clutch pedal assembly trying to fix the notorious squeaky clutch issue with my '05 access cab 4 cyl. manual 2wd non-prerunner.. I've posted on this before here.

I've had both tsb's done on the clutch the last time it was in for the problem, which was the fifth time or so to have this thing looked at/worked on. Re: worked on, that makes two times for the squeaky tsb jobs and one for the soft clutch feel tsb job, in hopes it would finally work, all this approved by 800number Toyota, after the 36k warranty was up. I now have 67k mi. and all this started at 20k mi. Of course it's still making lots of noises, more so in hotter weather, but it's still around now. I've video-documented its current state.

I was told arbitration is a longshot but with my record of all this, I may have a shot at something, in my world that would be a very fair or a bit beyond fair trade-in or buyback, toward the same truck, new version. My understanding is '07 and up problem solved via higher quality parts (?) Of course I've been blowing off getting motivated to fill out the arbitration paperwork, while still tracking the noise types and outside climate's effects, which seem to apply.

I know lots of '04-'06 owners have had major issues with the same thing, all in varying severeness. Comes and goes or is full-time. Although it doesn't "interfere with driving function" per Toyota, that's crap. I have clients in my truck all the time and it sure as hell interferes with my daily operation of the vehicle and doing business when there's a haunted house level of creaking coming out of the clutch in the middle of summer.

Today on the way home the pedal went totally soft and I lost the ability to catch enough traction to go over 40 mph. I did make it home. I've never blown a clutch out. I'm not super mechanical, but wouldn't a failing clutch pressure plate and all that start failing incrementally? My guess is the pedal assembly (and master cylinder?) may have failed, resulting in the inability to engage the rest of the mechanics that make it drive normally (pressure plate, flywheels, gears?).

So I'll be calling the dealer (Maund/Austin) who had the last major attempt at fixing it, and who I've committed to my latest service with. Then a call to Robin, my case rep at 800Toyota. My fear is Maund will say sorry pal, we looked at it and it needs a $1500 clutch job, it's all fried, instead of, yes the pedal assembly we've rebuilt twice is the culprit, no charge, we'll fix it and you can fill out your arbitration forms and send them in for whatever happens for you next.

Over a year ago, I researched centerforce and another brand of higher quality clutch parts. If I was keeping the truck, I'd have to take a hard look at upgrading. But at this point I'd like to move toward a new version. Since I can't sell the truck honestly without telling the buyer of all the problems, my view is Toyota will eventually need to address this issue via arbitration. I was told by the Maund service mgr. (old-school long time w/company guy) that Toyota used to step up in the old days and really help out in situations where their products seriously failed, not so much these days. I'm sure it's touchy, as this particular clutch problem has affected lots of people.

Until I talk with them tomorrow, it's hard to know what to do. I'm not too thrilled about having an independent shop try to assess what parts are fried or not, but I have major concerns about getting a high dollar repair thrown at me.

Any feedback would be great. Thanks

[DevinSixtySeven]

I'm confused, is the widespread problem the squeak, or the failed clutch?

I don't know your truck, but I do wonder if perhaps something failed simply from being taken apart so many times, maybe the last guy doing the work didn't button something up properly, during the soft clutch work? Just throwing out ideas.

Personally I'd get some grease for the squeak, and work with Toyota getting the clutch fixed. I've had a clutch go out before, it's a major PITA particularly when it happens on the road.

Good luck,
Sean

[dealingdawg]

Well, the squeak, creak, squeal noises coming from the clutch pedal assembly have been a widespread problem for a very long time. The sudden failing of the clutch was yesterday.

There's a local shop in my neighborhood that has a good reputation, so I'm letting them do the job. About $350 in labor to install oem parts I'm getting at a discount thru the local dealer's online parts store.

Clutch disc, clutch cover/pressure plate, throwout/release bearing, pilot bushing/bearing (these parts seem to have two names referring to the same thing), and rear main seal. All for about $300. Got a good deal on a rental for the weekend.

Dealer and 800Toyota had zero to offer. I will finally move on the arbitration paperwork submitting very soon.

As to whether anything to do with all these tear-downs of the clutch pedal assembly could have somehow related, who knows. I will be raising hell about the whole situation via arbitration, we'll see how it goes.

Grease was never a solution to the problem, quieted down for a couple hours and that's it.

[Slick]

I can only relate to you what happened to a friend that went to arbitration on a Ford F250 diesel. In Texas, if you win your case, the State, in their incredible wisdom, will make you pay for the mileage that you have put on the truck. His was $0.45 a mile. Considering you have 67,000 miles, you're basically screwed. Then you also get to pay attorney fees. Arbitration in Texas is a major joke and the auto makers know it. I would suggest getting it fixed as good as you cheaply can and get rid of it. Best of luck- you're gonna need it.

[lelandstanford]

Not to rub salt on your wound but if you have two dealers working on a same issue five times then you know either the design is flawed or dealer's ability.

One time I had a complaint about rattling noise from the suspension when go over bumps. Dealer's solution was tightening front license plate frame. I later discovered one of the brake caliper bolts was loose.

I would second Slick's suggestion: Fix the problem yourself and either keep or get rid of the vehicle to minimize lost.

[dealingdawg]

Hey Slick, I'll figure out the arbitration results for myself, the 'my friend had a Ford' story doesn't do anything for me.