Clutch Pressure Varies/Inconsistent

[TracerBullett]

2002 Sport trac, SOHC, Mazda R-5 tranny

Alrighty. The truck has been to the dealer twice for tranny issues. 1st was for the "typical" 3rd gear synchro that seems to be common dating back to my 1980 mustang. Different tranny but same problem. Second time, tranny fluid had mysteriously drained and when I caught it, it had less than a quart of fluid. As you drove the hight the rpm's the louder the tranny would whine.

Prior to the first dealer visit the clutch pressure was inconsistent. Some days it would be solid as soon as you would press it. Some days there was about an inch of play prior to the clutch engaging. I advised the dealer prior to both visits and they have insisted it was normal. I purchased a new slave cylinder just in case and the second time they took it apart they still insisted it was normal and decided not to change it out despite my request.

I have bled it on the off chance that there was air in the system even though the symptoms didn't point in that direction but to no avail. After the second visit things have been slightly worse and shifting when stopped can sometimes be a pain due to lack of pressure and I have to pump once or twice to get it into gear.

I have heard that their is a possible solution though I have not been able to get the details. Does any one out there have any experience with this, and can you provide a possible solution short of dumping the tranny and putting a t-5 in there (future plans for next time tranny decides it doesn't want to work). I'm at 37K miles and the dealer was useless even when in warranty so I don't see that as an option.

If anyone has any suggestions for an upgraded/better clutch and related parts I would appreciate the input as well. I'm not due but if I can't find an answer that may be my next step since I have to pull the tranny to swap the slave.

 

[Doug]

It sounds like you're having issues with the slave cylinder. Difficulty getting into gear is a classic sympton of a worn slave cylinder. Though it's suprising the slave cylinder is worn out after 37k miles, I got about 130k out of mine before i had to replace it. I suppose it's possible there is an issue with your master cylinder but I've never had to deal with that. As far as the transmission dumping fluid I've heard of that happening on older trucks where the rubber freeze plugs dry up and allow fluid to leak. However when that happens all the fluid is lost. I'm not quite sure what is up with your's I've got over 140k miles on my truck and my transmission is holding up. I'd try draining out the trans fluid and filling it up with either some synthetic trans fluid or some mercon V and a quart of lucas oil stabilizer. I added lucas oil stabilizer to my trans and it really helped smooth out the shifts.

 

[TracerBullett]

The fluid was new from the dealer and I replaced it with RP Synchromax a while back. It shifts smoother but the clutch pressure issue isn't related to that. I'm thinking the Slave is just garbage. The rubber freeze plug issue was resolved by ford on the newer models of this tranny, I believe. The fluid loss ended up being a bad input shaft seal which really was a shame because despite the pressure issue the shifting was smooth.

 

[Doug]

It's also possible there is an issue with your fly wheel. I've heard of people having clutch disengagement issues once they have had thier fly wheel cut but I doubt that would apply to you. If you havent done so already I'd have the slave cylinder changed and check the master cylinder to see if thats leaking.