M5R1 swap - Clutch, flywheel, and so on. what will and will not work together?

[MadMax_636]

My TK5 front bearing retainer is ruined. Causing me to not be able to use the transmission. Since the release bearing dug a groove on both ends of it. Making it impossible for it to be reused.

Im considering swapping a M5R1 into my truck. I just need to know what clutch parts i need to replace and what I can use a 2.8 clutch kit and flywheel or do I have to get a 4.0 clutch kit since they are the same in terms of flywheel.

 

[bobbywalter]

i just go all 4.0


there can be an issue with master and slave....depending on what you are starting with

 

[MadMax_636]

i just go all 4.0


there can be an issue with master and slave....depending on what you are starting with

I already accepted the fact ill have to replace the slave and master. The original master has a remote reservoir. Like the 4.0.

The reason I asked this was because i bought a clutch kit and flywheel years ago for the 2.8 and the flywheel didnt fit. It wouldnt fit/seat. The new clutch kit also didnt even fit on the old flywheel.

So I wanna make sure im getting all the right parts once.

 

[bobbywalter]

been there

 

[SenorNoob]

2.8 and 4.0 flywheel are definitely not the same... The 4.0 and 2.9 flywheel aren't the same. The 4.0 is much larger diameter.

Order everything for the same application and you should be fine. Assuming anyway that the 2.8 doesn't have an oddball flywheel attachment pattern that I've never heard of.

 

[MadMax_636]

2.8 and 4.0 flywheel are definitely not the same... The 4.0 and 2.9 flywheel aren't the same. The 4.0 is much larger diameter.

Order everything for the same application and you should be fine. Assuming anyway that the 2.8 doesn't have an oddball flywheel attachment pattern that I've never heard of.

So order the hydro clutch stuff for the M5R1, release bearing stuff, and get a flywheel and clutch kit for the 2.8? Ive got the flywheel and clutch for the 2.8. Still need the hydro conversion (The M5R1 master and slave)

 

[SenorNoob]

That's what I would expect. I can't say for sure that it'll work. Never owned a 2.8.

 

[MadMax_636]

Anyone know if the flywheel or clutch kit for a 4.0 will fit perfectly on a 2.8?

This is for anyone new.

I asked on this thread but no response so far. Based on @bbbc3 post https://www.therangerstation.com/fo...el-upgrade-for-2-8-rangers-discussion.184785/
He used 4.0 parts I just dont know which ones he used. Since I got a 2.8 flywheel and it didnt fit onto my 2.8... thanks Rock Auto...

 

[bbbc3]

Sorry I missed this post. Here is my order list from Rock auto. This is my stock 2.8l mated to an M5OD 4x4 transmission from a 91' ranger with a 4.0l.
I remember the clutch master cylinder connection not fitting the slave cylinder. I'm pretty sure this is because this was an odd year they change the fitting. Just be prepared to order an older style to make sure it fits.

Everything bolted right up and I've had no issues.

 

[bobbywalter]

as mentioned, key is a complete setup. a 90 or 91 4.0 ranger is close as you can get.

there are some differences between the master from 83-87 88-91 and 92 on. it is in how the quick connects and o rings ect work.

the later flywheels are 8 bolt as well so you dont want anything newer than 97 as it may be wrong....there is crossover with that 6 and 8 hole.


so bottom line, order a complete setup for a 1991 4.0 and you should be good to go. the pilot bearing or bushing should be the same across the model run....so get a complete system master/line/slave with the 4.0 flywheel clutch pressure plate/tob and pilot.

 

[broncc]

I'd like to note I've been running the 2.9 master for years and have been enjoying the benefits self-bleeding masters. If you go through my post history you will note I've had some issues, but I believe they came from a failing (stiffer) pressure plate. Now that I put a new one in, I notice an acceptable clutch force for driving in traffic and acceptable slave travel for shifting gears.

You will need to use a 4.0L clutch line. You either need to bend the hard line 90* or get the braided cable and enjoy more self-bleeding benefits.