Replaced my clutch today

[mr cribb]

I have finally replaced my clutch and slave today. Fortunately being military I have access to an on post repair shop. My biggest complaint:

trying to remove the slave line... the "white tab" that is supposed to be there according to ASE mechanics and the haynes manual... was NOT there. I was about to give up when one of the ASE techs came over with a thin piece of aluminum to wedge in.... after several hours of frustration and P**sing with it it finally came undone. The sad part is the shop closed up at 5pm so I couldn't get it done today.

All that is left is to bolt on the starter, xmsn x member, drive shaft, and exhaust. Then bleed the new slave.

My findings when I pulled out the old clutch was amazing to say the least. I want to say that it was a full 201k, the pressure plate was worn down a 1/16th - 1/8th inch (there was a worn lip on it), the clutch disc was down to rivets... (no wonder I couldn't pull up a hill in 2nd gear, much less 4th was almost non-existent. The slave looked fine, and I had outstanding pressure.

When I compared the new slave from Tousley Ford to my old one it said "made in Mexico" but had all the identical markings and numbers as the new one. I did go ahead and install the new one, just due to the PITA it is to put in.

All in all thank you to the explorer forum for posting the issues and tiring BS involved in tackling the job. I have learned lots. And I hope the slave bleeding goes with out a hitch. I need the truck for monday morning. I have 8 hrs to work on it tomorrow. I hope and pray it all works out.

 

[siguaw]

I just did the clutch on my 94 about a week ago. I bought this truck off the original owner and he had never had it replaced. Truck is about to turn 400,000 Kilometers "originally bought in canada" thats 248,548 miles. The only reason the clutch was even replaced was because the slave went out and with these you all know if you do one you might as well do the other. 17 yrs. on a factory clutch.. nice one ford.

 

[mr cribb]

Well mine was built in 12/91 so I guess it possible it could be original. I am the 2nd owner.

How easy was the bleeding process for you regarding the slave cylinder?

I have read multiple horror stories on how big of a PITA it is to do.

 

[siguaw]

i replaced the master at the same time so that my complete system would be new. I bench bled the master. hooked it up to the slave. Gravity bled the entire system. Then bled it just a few times like you would brakes. Small reservoir so be careful not to run it dry. After that i have plenty of clutch and have not looked at it again. Was very simple

 

[mr cribb]

Well I connected the line to my slave last night before I left it, I am hoping it goes like brake bleeding, I remember what kind of pressure I had before so I am going for that feeling.

 

[mr cribb]

I got it completed today at 330 Central Time.... I would've been done at 130 but I was tracking down a no start issue.... I thought it was the fenderwell solenoid I swapped it for the rear main seal I didn't need. Then to find out i was the stinkin battery. 10.23 volts by the shops battery tester.... It drove in there w/o any starting issues, how on earth did having it disconnected for over 24hrs kill it? It has sat for weeks on many occasions and I didn't start it and I never had an issue. Autozone tested it and said 11.23 and 0% reserve capacity. The battery was from 2004 so I guess it got it's use in life. I wasn't too happy about paying $100 for a battery though.

I replaced the fenderwell solenoid because it was having an issue 1 out of 4 tries attempting to start and since it was $10 I figured it was cheap insurance.

The clutch all I can say is WOW!!! My engagement is no longer near the top of pedal travel but barely off the floor..... and it pull hills in 4th gear without complaining back at me

Sorry for the long post but all in all I'm happy to be back in my explorer(it beats driving the wife's gas hog Durango), thanks again to all of you whom have experienced this job and provided feedback.