Clutch issue... not the norm! PLEASE HELP!!!

[Rangerdude1983]

Ok so here is the story. Put a new clutch kit and slave cylinder in my dad’s 2001 3.0 4x4 in let’s say, August of 2006. Truck drove flawlessly for a year, and then started to act up. On warm days (ambient temp above 75) the clutch begins to stop disengaging all the way. When the truck is cold, it drives fine. Only after it warms up for a few miles does it have the problem. And after it cools down again it is fine. The hydraulic line has its factory heat shielding, the clutch has been bled about, oh, 100 times lol (reverse, gravity, pressure) all to no avail. The first time it was bled the master was inverted to make sure it had no air in it. The last time I did it, and when I was done, I looked in the inspection cover at the pressure plate and there was a good 1/8-3/16 of clearance between plate and clutch disc. Three days later the truck started acting up again. And there is very little to no change in pedal effort when this happens, and it doesn’t drop or fade like anything is bypassing. No change in fluid level. Any ideas??? I am an ASE certified mechanic, and I have done 7 or 8 of these clutches between my own vehicles and work and have never had a problem like this. Any input would be greatly appreciated.

P.S. By the way the slave cylinder was and OE Motorcraft and the clutch was a Valeo.

 

[martin]

did you change the pilot bearing at the same time you changed the clutch?

 

[Rangerdude1983]

yeah it was changed and lubricated with hi-temp synthetic grease. i have had em' get rusty and keep the trans input shaft turning but usually i'll hear it squeaking first.

 

[feellnfroggy]

It sounds like your clutch fluid is burned up. i would try flushing the master cylinder and slave cylinder and put new fluid it. Check the clutch fluid line goin to the slave cylinder and make sure its not too close to the exhaust or sumthingto cause premature overheating.

 

[LearjetMinako]

Did you replace the slave cylinder with a OEM Motorcraft part? Or is it the orginal one from the factory?

I know you mentioned that you bled the clutch. It could be the fluid has absorbed moisture or the seal on the clutch res. is not sealing correctly. Just something to check.