Odd clutch problem
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Freshman User
Joined: Jun 2006
Posts: 31
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From: Missoula MT
Odd clutch problem
I have an '86 Aerostar with the 2.3 four, and 5-speed manual trans. It has about 170k on it.
A couple of weeks ago, I was driving up US 95 in Idaho, and drove up an 8%, 8 mile grade. I managed 45 mph in 3rd gear, and did okay. I should add that it was in the mid 90's that day. About 10 miles after reaching the top of the grade, I had to stop for construction. When the flagger motioned me to go, I put it in gear, and when I let out the clutch, nothing happened. I pushed it off to the side, and when I checked the brake master cylinder, it was almost empty. I sat there for about 45 minutes, trying to figure out what to do, and before I shut the hood, I checked the master cylinder again, and it had filled back up. I drove off without a problem, but it happened again about an hour later. Same thing-Once it sat for a while, it was fine, and I was able to drive the last 150 miles without incident. Since then, it has been fine, except that I notice it kind of "stutters" when I'm in 2nd gear, and let off the gas.
Did I just overheat and boil the fluid? Am I maybe getting some oil leakage on the clutch?
A couple of weeks ago, I was driving up US 95 in Idaho, and drove up an 8%, 8 mile grade. I managed 45 mph in 3rd gear, and did okay. I should add that it was in the mid 90's that day. About 10 miles after reaching the top of the grade, I had to stop for construction. When the flagger motioned me to go, I put it in gear, and when I let out the clutch, nothing happened. I pushed it off to the side, and when I checked the brake master cylinder, it was almost empty. I sat there for about 45 minutes, trying to figure out what to do, and before I shut the hood, I checked the master cylinder again, and it had filled back up. I drove off without a problem, but it happened again about an hour later. Same thing-Once it sat for a while, it was fine, and I was able to drive the last 150 miles without incident. Since then, it has been fine, except that I notice it kind of "stutters" when I'm in 2nd gear, and let off the gas.
Did I just overheat and boil the fluid? Am I maybe getting some oil leakage on the clutch?
Lead Driver
Joined: Sep 2003
Posts: 7,012
Likes: 204
From: SoCal
If you suspect oil leaking onto your clutch, look around the joint between the engine and bell housing. If the rear main seal is leaking, oil will show up in that area.
I hope you meant that you checked the clutch master cylinder. It does not seem right that it should be almost empty. It sounds like your pressure plate is not returning to clamp the clutch when you release the pedal. Maybe that's when the MC appeared empty, and when the plate finally returned, it pushed on the slave cylinder, which pushed fluid back into the master. I would check for any kind of binding in the slave cylinder or clutch release fork area.
I hope you meant that you checked the clutch master cylinder. It does not seem right that it should be almost empty. It sounds like your pressure plate is not returning to clamp the clutch when you release the pedal. Maybe that's when the MC appeared empty, and when the plate finally returned, it pushed on the slave cylinder, which pushed fluid back into the master. I would check for any kind of binding in the slave cylinder or clutch release fork area.
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Freshman User
Joined: Jun 2006
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From: Missoula MT
An update:
I haven't had a repeat of the problem until yesterday. Same thing-clutch wouldn't engage after about 40 minutes of around town driving. It sat for an hour, then it worked fine. I took it to my mechanic this morning, and he inspected the clutch, and said it was good, and oil free. It doesn't slip, so that makes sense. He said that he thought it was the slave cylinder overheating, but wouldn't be sure without R&R of the transmission. He suggested that I just drive it as is, and deal with the occasional problem, and I'm inclined to agree, since spending $500 on it right now isn't in my financial plan.
Anybody else ever had any heat related clutch problems?
I haven't had a repeat of the problem until yesterday. Same thing-clutch wouldn't engage after about 40 minutes of around town driving. It sat for an hour, then it worked fine. I took it to my mechanic this morning, and he inspected the clutch, and said it was good, and oil free. It doesn't slip, so that makes sense. He said that he thought it was the slave cylinder overheating, but wouldn't be sure without R&R of the transmission. He suggested that I just drive it as is, and deal with the occasional problem, and I'm inclined to agree, since spending $500 on it right now isn't in my financial plan.
Anybody else ever had any heat related clutch problems?
FTE Community Team
Joined: Nov 2001
Posts: 1,806
Likes: 244
From: Oak Harbor, Washington
I haven't heard of that symptom, but the slave cylinder is a PITA on Fords that use that design.
If it was mine, I would flush the clutch master & slave (use a whole quart of brake fluid) and see if the symptom changes. If not, you're up for a new clutch (everything, while you've got the trans out).
[later]
Thinking about it, one thing I have seen before is a brake master cylinder stick down, and the clutch master cylinder is basically a single-circuit version of the brake master cylinder. I suppose it's possible that the master cylinder has gone flaky. But my money is on the slave.
If it was mine, I would flush the clutch master & slave (use a whole quart of brake fluid) and see if the symptom changes. If not, you're up for a new clutch (everything, while you've got the trans out).
[later]
Thinking about it, one thing I have seen before is a brake master cylinder stick down, and the clutch master cylinder is basically a single-circuit version of the brake master cylinder. I suppose it's possible that the master cylinder has gone flaky. But my money is on the slave.
Post Fiend
Joined: Oct 2005
Posts: 5,242
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From: Kiev, Ukraine
There are two hypotesas
First - when tranny is hot slave stuck.
Second - when it is hot under hood MC piston stuck. MC may be removed from van easily, taken apart, cleaned and inspected inside. Onece I got internal spring broken and I purchased MC rebuild kit (made in China of course). Van was sold five years ago and keep running with old MC.
For slave no rebuild kits available... Mazda parts are expencive
First - when tranny is hot slave stuck.
Second - when it is hot under hood MC piston stuck. MC may be removed from van easily, taken apart, cleaned and inspected inside. Onece I got internal spring broken and I purchased MC rebuild kit (made in China of course). Van was sold five years ago and keep running with old MC.
For slave no rebuild kits available... Mazda parts are expencive
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FTE Community Team
Joined: Nov 2001
Posts: 1,806
Likes: 244
From: Oak Harbor, Washington
I don't know about the slave for Aeros, but for the F150s there are cheap alternatives to the OEM part that aren't that cheap -- an acquaintance put a cheap one in and had to replace it a year later. Lotta work for a 4WD F150.
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