Many times I get stuck in gear

Hi,

If you are low on fluid, that will most likely make this easier. First, check where the master cylinder is mounted on the fire wall (under the hood). Check for leaks. Do the same on the transmission where the slave cylinder is located. Since it was low on fluid, chances are you will see the leak.

Now, based on your description, I have a feeling it is the clutch master cylinder. However, there is only one way to be sure and that is by checking.

If you determine which one is leaking, here are the directions for replacement. First is the slave cylinder. The attached pics correlate with the directions.

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1999 Toyota Corolla CE Sedan L4-1.8L (1ZZ-FE)
Procedures
Vehicle Transmission and Drive-train Clutch Clutch Hydraulic System Clutch Slave Cylinder Service and Repair Procedures
PROCEDURES

pic 1

REMOVAL

pic 2

1. DISCONNECT CLUTCH LINE
a. Using SST, disconnect the clutch line.
SST 09023-00100
b. Use a container to catch the fluid.
2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYLINDER

DISASSEMBLY
1. REMOVE BLEEDER PLUG
2. REMOVE UNION BOLT, 2 GASKETS AND UNION
3. PULL OUT BOOT WITH PUSH ROD

pic 3

4. REMOVE PISTON
Using compressed air, remove the piston and the spring from the cylinder.

REASSEMBLY

pic 4

1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN
2. INSTALL PISTON WITH SPRING INTO CYLINDER
3. INSTALL BOOT WITH PUSH ROD TO CYLINDER
4. INSTALL UNION 2 GASKETS AND UNION BOLT
Torque: 24.5 Nm (250 kgf-cm, 18 ft. Lbs.)
5. INSTALL BLEEDER PLUG
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)

INSTALLATION
1. INSTALL RELEASE CYLINDER AND 2 BOLTS
Torque: 12 Nm (120 kgf-cm, 9 ft. Lbs.)

pic 5

2. CONNECT CLUTCH LINE
Using SST, connect the clutch line.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. Lbs.)
3. FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM
4. CHECK FOR LEAKS

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Here are the directions for the clutch master cylinder. When checking for leaks, also check under the dash where the clutch pedal attaches to the push rod.

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1999 Toyota Corolla CE Sedan L4-1.8L (1ZZ-FE)
Procedures
Vehicle Transmission and Drivetrain Clutch Clutch Hydraulic System Clutch Master Cylinder Service and Repair Procedures
PROCEDURES

pic 5

REMOVAL
1. REMOVE BRAKE BOOSTER
2. DRAW OUT FLUID WITH SYRINGE

pic 6

3. DISCONNECT CLUTCH LINE
a. Using SST, disconnect the clutch line.
SST 09023-00100
b. Use a container to catch the fluid.
4. REMOVE LOWER FINISH PANEL AND LOWER INSERT
5. REMOVE NO. 2 HEATER TO REGISTER DUCT
6. REMOVE CLIP AND PIN
7. REMOVE 2 MOUNTING NUTS AND PULL OUT MASTER CYLINDER
8. REMOVE GASKET FROM MASTER CYLINDER

DISASSEMBLY
1. REMOVE CLEVIS AND BOOT
a. Loosen the lock nut to remove the clevis and remove the lock nut.
B. Remove the boot.

Pic 7

2. REMOVE RESERVOIR TANK
a. Using a pin punch and hammer, drive out the slotted spring pin.
B. Remove the reservoir tank and grommet.

Pic 8

3. REMOVE PUSH ROD
a. While pushing the push rod, using snap ring pliers remove the snap ring.
B. Remove the push rod and washer.
4. REMOVE PISTON

REASSEMBLY

pic 9

1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER

pic 10

3. INSTALL PUSH ROD ASSEMBLY WITH NEW GASKET AND NEW WASHER
a. Install the washer to the push rod
b. Push the push rod to the piston, using snap ring pliers, install the snap ring.
C. Install the boot.
4. INSTALL RESERVOIR TANK
a. Install the reservoir tank and a new grommet.
B. Using a pin punch and hammer, drive in the slotted spring pin.

INSTALLATION
1. INSTALL NEW GASKET TO MASTER CYLINDER
2. INSTALL MASTER CYLINDER AND 2 MOUNTING NUTS
Torque: 12 Nm (120 kgf-cm, 9 ft. Lbs.)
3. INSTALL PIN AND CLIP
4. INSTALL NO. 2 NEATER TO REGISTER DUCT
5. INSTALL LOWER INSERT AND LOWER FINISH PANEL

pic 11

6. CONNECT CLUTCH LINE
Using SST, connect the clutch line.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. Lbs.)
7. FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM
8. INSTALL BRAKE BOOSTER
9. ADJUST CLUTCH PEDAL. Refer to Clutch Pedal Assembly; Service and Repair.
10. CHECK FOR LEAKS
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Hi,

I totally agree. Since the fluid level was low, you should be able to locate the problem. Let me know if I can help or if you have other questions.

Take care,
Joe

It has something to do with the hydraulics. I suspect it is the master cylinder, but check for leaks. Please feel free to let me know what you find or if you have other questions.

Joe

Air in the system could cause this, but the only way it would have gotten into it was if the system was opened.

You are very welcome and no problem at all as far as time. With everything happening in the world now, I'm just glad to hear you had a chance to get it fixed. Please feel free to come back in the future if you have questions or need help with anything.

Take care,
Joe

In all honesty, I suspect the clutch master cylinder is bad. I have a feeling it is allowing fluid to bypass the plunger at times and causing the problem. I realize the master cylinder was replaced, but the problem existed prior to the new clutch as well. If the master cylinder is allowing fluid to bypass, the fluid will likely not get lower.

When a slave goes bad, most times (not always) it will leak.

Joe

Hi,

That is correct. There is a plunger in the master cylinder that when worn, can allow fluid to bypass. Let me know if that takes care of the problem.

Take care,
Joe