Dealer messed up my clutch

[98mazdaman]

Hello All,

I originally took my 5 speed to the Ford dealer to have a new master and slave installed. Since then, my truck has been nothing but trouble. I've taken the truck back at least 5 times for the same problem: inconsistent clutch feel. When I first get the truck from the dealer, the clutch engages about 3/4 of the way off the floor. After a week or two, the clutch just moves all over the place, to barely off the floor to 3/4 off the floor. I can pump it a few times and it gets better. Sometimes it gets hard to engage or it grinds going into third. When I first get it from the dealer "fixed" it's as smooth as butter. The dealership has bled it multiple times as well as replaced the slave twice. I used to love driving this truck but now I can hardly stand it. The dealer can't seem to fix it and I sure don't know what to do with it. I'm talking about a Ford dealer too, not Mazda. I took it to Mazda about 5 years ago for the same thing and they fixed it right off the bat.

Any ideas how to fix this? I spent $1000 trying to get this thing fixed. I want to enjoy my truck again. I'm wondering if maybe they used the wrong fluid.

Thanks

 

[RonD]

It uses regular brake fluid

I would have them replace the Master and check the clutch pedal arm pivot for wear

There is a valve in the Master for the reservoir hose, when clutch pedal/master piston is all the way up there is no pressure in the system so if there was fluid lost, more fluid can run out of the reservoir and into the master to keep the system topped off.
When you press down on the pedal that valve should close to prevent fluid from being pushed up into the reservoir, if it is not closing instantly then you will get what you describe, changing disengage and engage pedal height.

The clutch pedal arm is on a shaft with the brake pedal, and it can start to wear out so pivot point changes.

#2 post in the thread has pictures of worn clutch/brake assembly: http://www.therangerstation.com/forums/showthread.php?t=66783
Click in the picture links

 

[98mazdaman]

Thank you RonD. I will crawl up under the dash as soon as I get some time to look up under there. That would make sense if that's indeed the problem.

 

[98mazdaman]

Is there a way to tell if the pedal assembly is bad without taking it off? I can wiggle the clutch pedal a little bit, but I can't see the side facing the floorboard to tell if the pivot point has worn out.

 

[98mazdaman]

I took the dash apart and inspected the pedal closely, pushing in the pedal and letting it out. There doesn't seem to be any lateral play or any cracks that I could find. I had a buddy push in on the clutch pedal while I looked into the reservoir. There didn't seem to be any change in fluid level. When he released the pedal quickly, there was a slight splash that came up from the reservoir...

I wonder if engaging about half an inch off the floor is just normal? I don't like it at all.

 

[RonD]

I know when my clutch disc is brand new, and thick, it could be hit and miss for the first few weeks, but it does go away.
My last clutch didn't have that issue, maybe the disc wasn't quite as thick, lol.
It did seem thinner, but it had been a few years, well more than a few

So could just be thinking everything is getting thinner and smaller, like clutch discs and newspaper print

 

[adsm08]

So could just be thinking everything is getting thinner and smaller, like clutch discs and newspaper print

Or my wallet. But oddly, not my wife.



Another thing you can do to test for air or leaks in the master and line is unhook the line at the slave and try to push the clutch in. Any air or leaks will allow the pedal to move, if it is solid any potential hydraulic issues would be in the slave.

A word of warning though, it is possible to bend the master cylinder push rod that way, so BE CAREFUL. I usually use my hand, not my foot for this test because I know my arm is not strong enough to bed the rod, but my leg is.

 

[Doofy]

I remember the days when mechanics honored their work and if they didn't fix the problem you didn't have to pay them. Sadly, those days are gone.

 

[98mazdaman]

Thanks everyone. I got another ford dealer to have a look at my truck next wednesday, as long as I bring the receipts for the repair from the other dealer. We will see how that goes.