[LRNAD90]

Okay, so I just spent the better part of my Sunday wrestling the Clutch Tower out of the truck, replacing the master, and reinstalling it back into the truck. But something seems very wrong. Neither of the helper springs have been reinstalled, but there is no resistance till the clutch is almost to the floor, and then heavy resistance for the last half inch of travel.

I haven't bled the system yet, but this doesn't seem right at all. The pedal is adjusted to 5.5 off the floor, per the manual, and I did my best to adjust the rod with some 'freeplay' per this video, but I have to admit I must be missing something with the freeplay adjustment, and I am concerned that I may have 'too much throw' and I am bottoming out the clutch master's stroke, and will damage it?

Where exactly is the freeplay supposed to be? I mean there is always play in the master cylinder plunger, as it moves by design. I've looked at the diagrams in the factory service manual, searched online and watched videos like the one linked above, but I must be dense, because its not making any sense at the moment..

Clutch pedal (even without the springs) sits/returns to the top of the travel/ all the way 'up' position. Maybe I need to drink beer while I'm doing this (feels like the only thing I haven't tried)..

I took a short video of the linkage movement while I moved the pedal. The first two actuations are the amount that has no resistance, then two actuations all the way to the floor. But it looks like it is too big to upload, so not sure why I am even mentioning it..

 

[LRNAD90]

Maybe that is all it is. Guess I will find out tonight..

 

[LRNAD90]

You need to bleed all of the air out first. It can't do anything until then.

Well, I feel like an idiot, but Red was right once again. I started to try to bleed it last night, but wasn't getting anything out of the slave bleed nipple, and I'd had enough for the day. Got out the Motive pressure bleeder today, and that did the trick. I was able to push out lots of crappy gray fluid and air bubbles. Probably used a full bottle of Castrol DOT 4, but at least I know its flushed out now.

 

[LRNAD90]

OK, it's flushed.
But, does it work as expected?

Well it was, but then..

Another Clutch Adjustment Question

So after replacing the master cylinder (several hundred miles later for some reason), I started experiencing clutch slip under load. Clutch is factory original with 38K miles, so fairly sure its not the clutch. It has been suggested the free-play adjustment is wrong, and several members have...

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