hopefully y'all can help me out with this one... hopefully it isn't anything too intensive... went to press my clutch in tonight to fire the truck up and i heard a loud "pop" clutch immediately went straight to floor and the only thing that would bring it back was the return spring on the pedal mechanism.. when the clutch is fully depressed, it is not engaged because it will not start. i expect it could possibly be the master cylinder linkage? what else could it be? i havent had any problems with my clutch. all help is greatly appreciated.. cheers!

 

either that or its the clutch fork hope for the master cylinder

 

my truck did that and it was my slave cylinder i had to remove the transfer case transmission to replace it. if your lucky its an external one and will be just a few bolts. is there any fluid leaking out? if so where is it leaking from if its with in the bell housing you need a new slave cylinder or a new clutch line if the line is loose underneath. Clutch fluid is hygroscopic and absorbs moisture over time so when winter comes its best to drain the clutch fluid every 3 or 4 years to keep from having a blow out like i did

 

just an update... got everything fixed today!! turns out it was the plastic sleeve at the end of the clutch pushrod to the master cylinder... picture: http://www.am-autoimages.com/partima...54442/main.JPG

the plastic wore away and gave out... should have been an easy fix, but the rod would not come out of the master cylinder due to the prongs that keep it in place. ended up having to replace the whole master cylinder... got it at cost though for under $40. helps to know mechanics ended up getting a set of 31s for free too.. ill upload pictures soon.. goodnight y'all!!

 

So I just installed a new flywheel, clutch, and transmission. Had no issues installing them and everything went in as should. The only thing I had trouble was pushing the hydraulic line into the new slave cylinder, it was harder than heck! Eventually got it but it didn't seem right the clip you put on it wasn't really locking it in, didn't see anything else we could do so we just left it and continued.

It started up fine and drove ok... Clutch was really touchy! Like if you lift the pedal up at all it was disengaged already... That was one issue I had I thought I bled it but maybe not enough? ? ?

Then driving home with it and POP!! the pedal went straight to the floor and died. So immediately I checked that hydraulic line sure enough that popped out but also there seemed to be plastic pieces on the floor mat.

Any thought to the hydraulic line? and where could I find a plastic clip that does something with the clutch pedal?

Thanks all having some major issues with this truck so far but once its going I LOVE IT!!

 

Without posting pics or a bunch of links just look through the first page of my library, http://s1240.photobucket.com/user/bl...?sort=3&page=1

Take it from me, pull the pedal tree and replace the bushings. If the master cylinder push rod is the broken plastic just replace the m.cyl. Rigging it is really NOT worth the trouble!

 

Ok so I installed new clutch and tranny myself and hired out someone to install a new master cylinder and push rod. They bled the system and now driving it around its slow to shift and the clutch still disengages not even a inch off the carpet. Does this sound normal?

It doesn't feel like it used to driving around. Its winter now so colder, the tranny fluid I put in was mercon v ATF I believe It's stated what Ford calls out for this tranny. Should I have put the 80W90 gear oil in it for winter? would that shift better for cold weather?

 

I assume this is in a 1994 and a 5 speed transmission. Under no circumstances do you ever want to put 80W90 gear oil in that transmission. The transmission bearings were designed to take ATF. Mercon ATF is correct.

 

Ok sounds good. Yes it's a 94 302 manual. Maybe it's a new clutch and I'm not used to it, but when shifting I have to wait and then let it in gear slowly. Sometimes have to hit the clutch twice to get it in gear. Any thoughts on that? I don't think I could have installed anything wrong. I think they didn't get all the air our of the line.

 

Pedal travel needs adjusted at a minimum. Shouldn't be disengaging that close to the floor.