Hey bro. I was just getting ready to post my own similar question in here but I am about a month ahead of you with clutch headaches. I have an 89, 250, 5 speed.......I was having inconsistant clutch pedal travel for quite a while (sometimes full pedal travel and sometimes it would engage when the pedal was an inch off the floor) Then one day it just went out completely and the clutch pedal hit the floor and I had no clutch at all. Since then I have replaced the clutch master cylinder and tried to bleed it unsuccessfully. I have spent all my free time three weekends in a row trying different things and methods of bleeding this animal.. I finally decided that I had probably gotten a faulty replacement part and this morning I went to the part store and bought another one with the intention of returning the other one when I got the truck running. I am at the same point in the process. I cannot seem to get good fluid flow down at the slave cylinder????? I may need someone to help me bleed it down but I have been keeping a piece of tubing from the bleeder down to a bottle of hydraulic fluid just as I would if I was bleeding brakes. I also tried to just let it gravity bleed itself. So far I am clueless as to what is going on and I relish the thought of having my rig taken out on a flatbed to let someone else fix it. I cringe at the thought of any one wrenching on my own rig when I have the knowledge and time to do it myself.........As for your problem. Look under the dash and see it the push rod from the clutch master cylinder is still attached to the clutch pedal pin assembly. That is where you should start. There is a plastic insert that holds it on to the pedal pin. If the plastic wore out then you might need to reattach it some how. From there I would say that your noise could have been originating in the throwout bearing at the slave cylinder down in the tranny. If your clutch was not slipping and it was just making noise then you could possibly get out of this by having the clutch master cylinder replaced but that will put you to the same point as I am right now.. Pissed off, frustrated, and in need of someone to telll me what the F--K i'm doing. I am a shade tree mechanic but I will do just about anything including changing cranks and bearings and fulll motor rebuilds to swapping body parts and wiring harnesses......Good luck and IF ANY BODY THAT READS THIS CAN HELP ME, PLEASE CHIME IN
