After 220k miles, my 1996 4WD 2.7L Tacoma developed an intermittent squeak when the clutch is depressed, and sometimes only upon release. There is no obvious connection to weather, etc. I first noticed it on a hilly, low- speed dirt road this summer. It will go away for hours or even days, then return, mostly during frequent shifting.
This is a separate issue from the other common squeak caused by lack of grease on the pivot arm inside the bell housing.
According to TSB TC005-99, on 4-cylinder models you're supposed to replace the entire Clutch Pedal Support Bracket [RZN] (formerly P/N 55107-35040) with the redesigned bracket (P/N 55107-04010). But it doesn't explain exactly what's causing the squeak, which sounds like rubber on metal (or wet rubber). At one point I thought it was my shoe squeaking on the pedal; a similar sound.
I asked a dealer mechanic the exact reason for the squeak but he only knew of the V6 issue, which involves replacing the U-bushing on the torsion spring (the TSB recommends NO grease for the V6 or the L4). The 4-cyl. apparently has a different pedal mechanism but I'm not sure how it differs.
This issue appears on Tacoma web forums but nobody seems to understand the true source of the squeak. You read the usual assumptions about using grease (NOT recommended in the TSB) or tightening the pushrod nuts, which never quite fixes the problem.
I don't understand why you'd have to replace the entire Clutch Pedal Support Bracket (for $100) after it's worked w/o noise for 220k miles. Does the bracket get warped over time? What exactly is causing the noise?
Thanks for any technical info. - Jack -