On the adjustable master cylinder push rod there is a "cushon" block which I believe was modified around 1986. This block is a metal housing with a rubber block trapped inside mounted on a metal pad. This tends to rub on the sides of the housing, thus causing a squeak. It is possible to dismantle the assembly and pack it with 'copperease' or similar grease. I think the older units were of a more solid design.
Article by David Harris
Date: Mon, 31 Jul 95 10:37:02 -0700 From: Ken Sumrall <email@example.com> To: firstname.lastname@example.org Subject: Squeaky clutch... my solution Hi gang, I read the messages about the squeaky clutch with great interest, because my clutch was getting more and more squeaky all the time. After Greta posted about the cushion block, I got ambitious this weekend and started taking my cluth pedal apart. After a bit of squirming and pain (lying on my back to get at the push rod) I got the cleavis detached from the pedal, and then got the cleavis detached from the pushrod. The cushion block that Greta mentions in her message is called a cleavis in the Toyota service manual. Once I had the cleavis out, I twisted and pushed and turned that thing, but it refused to squeak for me, so I decided I had a problem elsewhere. I then noticed that there was a plastic bushing in the hole where the pin attached the pedal to the cleavis. This bushing was shot. Half of the plastic was worn through, and it was almost in two pieces. I then looked at the pin, and it had grooves worn in it where it was rubbing against the metal. It also had a lot of dirt caked on the surface of the pin. I cleaned the pin with a spinning wire brush on my drill press, and cleaned the hole in the pedal, the cleavis and the remains of the bushing with some alcohol. I then lubricated the pedal/cleavis hinge point with some good grease, and put it all back together. Presto! No more squeak. Today I called the local Toyota dealer, and the parts guys will sell me a new pin for $2.05, and a plastic bushing for $2.05. I've ordered the parts. (See below) Just thought my experience might help some others. Ken Sumrall and Merlin, black '91T with T-tops.
Here are the part numbers for the pin and bushing for a '91 model (others should be the same I think). 90240-08071 PIN 90386-08033 BUSH Geoff Seeley