i have an '04 with the manual zf6. the problem seemed to start after the cab came off to do head studs.

sitting stopped at idle it can be impossible to get into gear unless i shut it off or pump the clutch and sometimes i can get 2nd and inch forward and get into 1st.

if i unscrew the reservoir cap and then back on it seems to get a little better for awhile.

has a new centerforce dual friction clutch, throwout bearing and fluid reservoir.

could it be the pilot bearing or bent fork? there doesnt seem to be too much peddle free play.

thanks in advance for any help.

 

Id say slave cylinder/master cylinder. I had the same problem after playing in the mud. Something that might help you like it did me is to climb under the truck push in and unscrew the slave cylinder. Pull the end out enough to have some up and down movement. The push it all the way back in. Do it a few times and it should get better. But won't fix it completely. Be sure to top off the master cylinder afterwards if needed.