Im spent, clutch problems... after rebuild.

[Akamuwhite]

1996 4.0 4X4 Ranger Ex Cab.
M5OD-R1

I'm about done with this truck. I've spent two full weekends under the truck rolling round in oil.

I recently had my transmission (M5OD-R1) rebuilt by a local shop, while I had the transmission out I thought it would be a good idea to replace the clutch, master and slave cylinders and have my transfer case reconditioned by the shop. I installed the trans, transfer case, clutch, flywheel, slave and master, clutch hydraulic line this weekend. I'm tired and spent.

This happens to be my first clutch in a rear wheel drive vehicle, but I have done one in a front wheel drive with a buddy a couple of years ago. I don't know where I'm messing up. The clutch seems to have proper pressure and I bleed it according to the instructions and video, but now that I have everything back together, it will not disengage enough to shift into any of the gears without extreme force. I'm at a loss...

When I look into the bell housing you can see the slave pushing onto clutch, which, to me, looks like a significant amount. When the clutch pedal is fully released, the slave cylinder appears to have a slight "wobble" to it, I have no clue if this is normal or not.

I really, really do not want to pull it all out again if there is something that can be done from the outside... please help. Thank you.

 

[4x4junkie]

It sounds to me like there's still air in it.
My best advise is to keep at it, trying different ways until you get it.

For me, I had success by cracking the bleeder open only slightly, and then VERY rapidly & forcibly cycling the clutch pedal about a dozen times in quick succession.
I've also heard of someone attaching a vacuum pump to the reservoir and sucking the air out of the system that way.

RBV clutches are a pain no doubt due to how the MC is mounted. Hope that helps.

 

[Akamuwhite]

Kept trying with the bleeding of the clutch... spent about 3 full days trying different techniques... no luck... so today I tore it all apart again... I found my pilot bearing crimped in half and it just fell out when I pulled the tranny away from the clutch... not too sure if this is a good thing or not, so, I'm going to try again, bought a new bearing and hopefully I can get it right tomorrow... if you've got any suggestions as to what I did wrong, please let me know.

Thanks.

 

[fyre82]

Line them up nice and straight. I used long bolts in the alignment pin holes, mine had threads in there, and just pulled the trans in slow.
The first time I got it cocked a bit and the slave leaked, so out it came again.

I really didn't have probs with bleeding the FM145 slave except for running it dry more than once.

 

[Eaglefixer]

read this link and check the pedal bushing http://www.therangerstation.com/forums/showthread.php?t=67723

 

[alwaysFlOoReD]

read this link and check the pedal bushing http://www.therangerstation.com/forums/showthread.php?t=67723

^^^Wow!
Another possibility that I've run into is the mounting flange [the ear the bolt goes through] has busted off and you can't tell until you look while someone else pumps the pedal. I've also seen firewall stress cracks that allow, or are caused by, unwanted movement.
Good luck,

Richard