Clutch problems/Will not shift into Gear on a 2003 ST 4x4

[gguerra]

My 03 ST 4x4 recently was having clutch problems. I was having to press the clutch all the way down to engage the clutch. Then all of a sudden I could not put into gear. I can put it in gear when it is off and when I start it the truck starts to move.

It has 144k miles on it with the original clutch. I thought, well I'm finally going to have to replace it. I bought the clutch kit, slave cylinder and took it into the shop. They tore it apart and replaced the clutch, slave cylinder and seals. I'm not sure if they resurfaced the flywheel but they probably did. Once they put it all back together, it was doing the same thing. Could not put into gear when the truck was on. SO, we replaced the master cylinder thinking what else if left, well nothing, it's doing the same thing. Lines have been bled, it should all work, right? I am now at a loss as to what else it could be. The shop was already going to start tearing it apart again but I decided to pose the question here? Any ideas?

After talking with a mechanic friend he suggested it could be the lines still have air in them which results in no pressure? Defective master cylinder? defective clutch plate?, clutch plate mounted wrong? At this point it is all a guess.

 

[Klondike]

I realize this thread is old and if the mods want to move it I'm cool with that.

I've had the same challenge with my 02: did you ever get any answer to this? what did you do to get it fixed?

I've looked for a tutorial on replacing the master cylinder, I'm know people on here have done it, I can figure out how to properly bench bleed it, just haven't done one before... any links to a thread would be awesome!

 

[RangerX]

Do you have any slop movement in the pedals? A problem in earlier (90s) Fords was the clutch pedal bracket would wear away or crack apart right at the pivot point at the top of pedal. That would reduce the actual pedal travel and not allow the clutch to disengage enough to shift.
I don't know if this happens on later models, but I'm throwing it out there in case it helps.

 

[Klondike]

I do not. Looks good. And the operation of the pedal is good. Also a relatively new slave splinder too.