Clutch Pedal Intermittently Sticking to Floor

I have a 2015 Tacoma with a clutch pedal that has started to stay "stuck" to the floor when releasing the pedal on occassion. The clutch pedal, slave cylinder and clutch fork movements are in-sync with the pedal motion. The clutch pedal back pressure also feels normal all the way to the floor, and also on release (if not stuck to the floor) so I do not suspect any issues with the master cylinder, slave cylinder or the clutch pressure plate back pressure through the fork assembly. Also no issues changing gears when the pedal is pressed, again confirming clutch is fully disengaged so no issues with master cylinder, slave or clutch pressure plate action. Clutch pedal only hangs up on release after fully depressed to the floor occasionally.

I did noticed it seemed the clutch pedal subassembly had some possible excessive play at its pivot bolt and suspected the pedal bushings were possible worn causing the clutch pedal sub-assembly to possibly bind and hang up. I removed the pedal sub-assembly and the bushings seem fine. I am wondering if it is possible the slot where the torsion spring slides in the plastic pedal sub-assembly (why plastic???) is worn abnormally and causing the torsion spring to hang-up and not slide efficiently when pedal fully deflected to the floor.

Attached is picture of the pedal sub-assembly slot where the torsion spring interfaces. Can anyone confirm if the slot looks normal or not? Anyone else have similar issues?

ISSUE NOW RESOLVED - Cause was actually a corroded release bearing action causing hang-up. See below post for details

 

I just replaced those parts you circled as part of also replacing the master cylinder. My pedal had the slop you talk of and those parts took out most of the play.......at least as tested on the bench, as I have not installed the assembly back in the truck.
Take a careful look a the clutch turnover spring at the top of the pedal and its holder. I noticed that without the hydraulics connected the pedal will go to the floor and stay there.

 

How many miles on the truck? I'd still suspect slave cylinder. Have you tried bleeding the clutch?

 

OP, yeah, same question as ^^^, how many miles you got.

As far a the notch you show on the pedal I am going to replace the cruise control cancel switch on the mounting bracket this morning and will check to see if the spring rides in the top of that "V" or in the bottom.

 

OK, so I got the clutch pedal support assembly mounted. The top of the clutch pedal looks just like yours in the pic and the tab of the turnover spring sits in the bottom of the saddle.

The hydraulics have not yet been connected. With the pedal at rest in the up position if I push it down about a third of the way and let go it will return upward to its rest position. But if pressed down to about half way or more it will go to the floor and stay there. I'll report back more as it goes together.

 

UPDATE - Issue now resolved.

FYI my 2015 Tacoma has 125,000 km.

The issue ended up being corrosion on either the slide action of the release bearing and/or the pressure plate finger pivots (likely the release bearing). When the truck was at operating temperature the release bearing/fork motion was very "creaky" and the corrosion was preventing the clutch from releasing smoothly, or not at all (when it was cold it was fine - though not as smooth as it should be).

Sprayed the release bearing good on both side with Deep Creep penetrating fluid then with a slightly heavier Krown penetrating/undercoating oil through the release fork access port. Then started the engine (with the truck on a hoist) and sprayed Krown at the pressure plate release fingers base pivot points. Grease was also added under the release fork pivot.

Took the truck for a good drive to get up to operating temperature and ensure the oil was got exercised well through out the release actions. The clutch action is now "butter smooth", no more hang-ups.

I suspect the cause of the seemingly excessive corrosion is from road salts used in the winter in my area and the fact the clutch housing has a lot of air vent ports. I replaced a clutch on my previous 2003 Sonoma with 180,000 km after 13 years and it did not have as much corrosion on the clutch pressure plate fingers. The Sonoma had only one air opening when the clutch hydraulic line enter the housing to the throwout bearing. The Tacoma has vents on the release fork and also an air vent towards the top of the clutch housing on the left side (3 finger widths wide).

 

This is normal pedal action due to the action of the torsion spring after it is past halfway to the floor. The torsion spring "toggles" force direction in the opposition direction (i.e. towards the floor) pasted the halfway point. Watch the torsion spring relative to the pedal attachment point as you deflect the pedal - you will see what I am saying. I noticed the same thing with mine and thought is was a little confusing at first but it actually makes sense now. It appears Toyota designed the torsion spring action to assist in disengaging the clutch beyond half pedal deflection. The master cylinder will counter action this downward deflection force caused by the clutch pedal torsion spring by the back pressure provided by the clutch pressure plate fingers (through the release bearing, release fork, slave cylinder and fluid up to the master cylinder).

It can make things a little difficult to diagnosis issues without appreciating the counter intuitive pedal response caused by the pedal torsion spring action.

 

Time to do the steel FJ pedal mod.