Clutch MC Pushrod Adjustment

[mobbedstude]

I have a 94 Ranger with a very strange clutch pedal situation. Ever since I had the truck, the pedal throw was very minimal. It disengaged fine, but had only enough throw on the pedal to engage and disengage. This made it tough since I had about 1/16" of play on the floor before she engaged.

I decided to see if there was an adjustment on the pedal one day. After poking around, I pulled on the push rod, and somehow got the pedal to lift up into a different position. I now had easily twice the pedal throw. The clutch then disengaged almost immediately when pressing the pedal (as before), but I had nearly 1-2" of room off the floor before it engaged. This was fantastic.

I took the truck in for tires, and the mechanic tried starting the truck while in gear and without the clutch depressed, therefore launching forward. After getting the truck back, I'm back in the same situation as I started. Barely any clutch throw. I took the pushrod off of the pedal, put the pedal where I wanted it, and the eye of the pushrod is about an inch away from the pin in the pedal. I cannot get the pushrod to pull out where I want it again.

Anyone ever run into this?

 

[alwaysFlOoReD]

I've had the problem but it was the master cylinder bolt flange. One ear was broken allowing the master to flex almost 3/4" before feeling anything at the pedal. I fixed with metal plumbers ?tape? screwed over the master onto the firewall with self tapping screws.

Richard

 

[pcollins]

I just love the fact that a MECHANIC turned the key on a 5 speed without the clutch in....wtf?

 

[Sasquatch_Ryda]

It shouldn't have started anyways.....

 

[mobbedstude]

I've inspected the master numerous times, and there are no visual defects. It's almost as if fluid passed the piston and got to the rod side, not allowing it to fully retract (though this cannot be the case). But when I pulled it into the better position previously, I was not doing anything scientific, just pulling.

The only way that it is possible to get the pedal in the better position is if the pushrod is able to retract out of the cylinder more. While I had the better pedal position, I was able to use full pedal throw for about 10k miles without any problems. I've searched all over online for a similar situation, with no luck. Strange.

Just out of curiosity, how does the clutch pedal look in relation to the brake pedal when in proper operation? Right now, they both are about the same height off the floor. When I had the better setup, the clutch pedal was much more towards me.