Hi all, having an ongoing problem with my clutch not releasing fully. I replaced my master and slave cylinder and put in a new one piece line as well, bled them fully, and it was much better for about a week. Now I'm forced to synchro shift again. The new issue seems to be that the pedal travels about halfway, then the piston into the master cylinder won't go any farther and instead the pedal bracket shifts to the side as you keep forcing it. It doesn't even go far enough now to engage the starter lockout switch, so yesterday I had to cut the wires from that and connect them directly.

I disconnected the line from the master cylinder and the pedal traveled fine like that, the bracket doesn't look to be cracked anywhere. But the problem came back immediately when I reconnected the line. Bleeding the system again didn't help at all.

 

You may be having throw out bearing travel problems ..seems unlikely the problem would still persist with a whole new hydraulic system ...have you tried disconnecting the slave cylinder from the transmission removing it from the shift fork pocket leaving the line on ...then push the clutch if it travels to the floor ...then you have a throw out bearing or throw out bearing fork problem and or possible mechanical motion problem

 

Thanks for that test! Yeah, the slave cylinder manages full piston travel when not bolted onto the transmission, so it's internal... as an addendum, normally I wouldn't even mention that the transmission was coated in fluid because usually the whole underside of the truck is, but I sprayed it clean while I was replacing the slave cylinder, and now it's covered in fluid again, so perhaps the throwout bearing isn't lubed? Is there an inspection plate for the clutch down there? Sorry, I don't have a shop manual handy.

 

The throw out bearing is a dry system it helps to add a little axle grease to the input shaft it rides on to aid in operation and keeping it cooler ...

If you get full travel with out it hooked up ..sounds like you have a mechanical bind or something isn't quite right in there ..if its manual transmission fluid covering the tranny ..it maybe time to pull it out and inspect the clutch assembly and thro bearing .as well as the seals and or rear main seal

 

Damn... I don't have a garage to work in or a second vehicle, so dropping the transmission is out for me as a DIY job... if I pay someone to fix this, should I just have them put in a fresh clutch?

 

Well it depends if the clutch is in good shape then possible to reuse it if its not soaked in oil though
And of course if its worn out .def replace it ...you can save yourself some cash buy purchasing a clutch kit at a local parts store usually a lot cheaper than having the shop double over charge you on a clutch
And bring them the parts ...for them to install while there fixing the possible throw out bearing or clutch fork problem wich shouldn't take very long

 

Your clutch is fine stop screwing with it. Look up at your clutch/brake pedal bracket above the steering column and you'll find its broken. That is a very common issue on that generation.

 

Is there a way to inspect the clutch without dropping the transmission?

 

Not really .. None that would be worth while . To gain any viewing point of the clutch and throw out bearing assembly ... Make sure your pedal bracket is not broken like white trash stated .... So you don't go barking up the wrong tree

If it ain't slipping don't mess with it ... If it has high mileage and you don't suspect it has been changed buy previous owner than go for a clutch to .. Might as well sense there gonna be in there ....if it does turn out to be a mechanical problem

 

Alright, I guess I'll have a clutch handy in case, and return it if not needed.

It's definitely not the bracket.

 

.yea it's a toss up either buy and have them put it in or ..if you plan to hold onto the truck for some time just go ahead and put it in ...save yourself some future work and money ...down the road .