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  #1  
Old 10-03-2010, 10:39 PM
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Default 1993 Explorer Clutch Trouble

1993 Ford Explorer sport 2wd 5spd

Truck has a brand new clutch kit. Pedal went limp, figured it was the slave cylinder. Old slave cylinder looked fine upon removal but swapped in a new one anyway. Didn't fix the problem. Bled all air from the system. Already pulled the master cylinder and it looks fine but gonna swap in a new one in the morning anyway.


Anyone have any thoughts on what else it could be?

Also, I could strangle the Ford engineer that thought it was a good idea to install the slave cylinder inside the bell housing. Freakin idiots. Had to pull the transmission just to change the slave cylinder.
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Old 10-03-2010, 10:42 PM
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Master cylinder.Also fords take FOREVER to bleed.

EDIT* Wanted to add that after you change the master out you can try to let it gravity bleed for an hour or 2.It may make bleeding faster for you.

Last edited by sound_around; 10-03-2010 at 10:49 PM.
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Old 10-04-2010, 01:36 PM
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Installed the new master cylinder this morning. Didn't fix it. The only part left in the system is the clutch hose that runs from the master to slave cylinder. Dealership item that cost $88 dollars.

Since I now have the entire old assembly outside of the vehicle we hooked it all up and ran water through for testing. Everything works perfect. Master cylinder pumps, slave cylinder moves freely, and all hoses are clear.

I thought we had just put this clutch kit in last Christmas but looked it up and it was two years ago. Clutch still engages fine inside the transmission. I can crank the truck in gear and drive it, just can't shift gears. Checked out the slave cylinder through the access hole in the transmission and it seems to be fully extended against the pressure plate (explains why I have no pedal pressure). Now I'm really confused. I'm no expert but I would think that the transmission would be stuck in neutral at this point yet it's the opposite.

I'm guessing the next step is a new clutch kit.
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Old 10-04-2010, 01:52 PM
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Throwout bearing may have collapsed some or maybe the clutch fingers or the springs on the pressure plate are failing.

With the system off the truck there is pressure on the slave rod to test accurately.
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Old 10-04-2010, 01:56 PM
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didn't mazda make those manual transmissions?
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Old 10-04-2010, 01:58 PM
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Quote:
Originally Posted by mhart View Post
didn't mazda make those manual transmissions?
Yes.
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Old 10-04-2010, 02:05 PM
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The Mazda built m5od series can be found on tons of cars and has proven to be a decent product.

Mazda M5OD transmission - Wikipedia, the free encyclopedia
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Old 10-04-2010, 08:45 PM
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Finally got it fixed. The main issue was a bad slave cylinder but it caused a second issue, air in the master cylinder. Apparently these models in particular are really bad about getting air trapped in them and the only way to get it out is to unbolt the master cylinder and bleed it upside down. What a pain! I got lucky and found a clutch website that described the problem and fix in detail & even had a 8min youtube vid about it.
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Old 10-04-2010, 10:44 PM
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glad to hear you got it fixed. anything with brakes or a transmission are usually a real pita.
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Old 10-04-2010, 10:56 PM
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Quote:
Originally Posted by Derrick824 View Post
Finally got it fixed. The main issue was a bad slave cylinder but it caused a second issue, air in the master cylinder. Apparently these models in particular are really bad about getting air trapped in them and the only way to get it out is to unbolt the master cylinder and bleed it upside down. What a pain! I got lucky and found a clutch website that described the problem and fix in detail & even had a 8min youtube vid about it.

Very nice!You make me miss my AWD 5speed Exploder.....And all 5 Supercoupes

I have had to do that (upside down bleeding) before myself but for some reason I forgot all about it.
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