In my 99 with a zf6 it seems like when I push the clutch to the floor it's not disengaging all the way. It has a newer valair clutch in it maybe 15000 miles on it. It's really hard to get the truck in reverse or first from a stop. If the truck is stopped and it's in reverse or first with the clutch to the floor it will move in that gear. Is there a adjustment on the clutch? I'm thinking no since its hydraulic

 

Have you checked the fluid level?

 

Bad hydraulics will make it act like that. Did you change the hydraulics when you changed the clutch? They always seem to go out shortly after the clutch.

I've had hydraulics fail where you had trouble getting it into gear when at a stop.

 

Yes fluid is full. It's really hard to get into gear at stop.

 

im onboard with chris, in this situation. i find im replacing the master/slave assy (as a complete pre-bled unit) every year to year and a half...i order from Advance Auto...p/n PF9021. Its all aluminum, and for me, has lasted longer then the dorman plastic assy's....

 

About how long does it take to replace for you looks easy

 

After you've done it a few times, maybe 15 minutes.

 

So I replaced the slave and master cylinder and still have the same problem.

 

Since you have a 99, have you ever replaced the shift fork? The early ones were known to bend.

Pull the slave and measure the distance between the bell housing and the fork. Here's one that's not bent.

 

No I haven't. But the problem seems to get worse when the engine is hotter. This morning it acted fine for a while then started acting up when it got hot

 

mines has thatproblem. I dread summertime, forthis very reason. i find swapping the m/s assy buys me enough time thru summer and winter. Then replace AGAIN come summertime, lol....if im into the throttle in 4th, then grab 5th, the pedal goes to the floor with barely any resistance. Always thoguht, the hot fluid had a part in the sloppy clutch pedal, when warm...

 

Fine cold and different hot sounds odd. How does your fluid look and is it full? What type of fluid do you have in the transmission?

The bent fork would be the same all the time. Worn synchros should be the same all the time as well. I've seen the clutch hydraulics act worse as the temperatures heated up, but you've replaced those already.

 

I measured like you did In the pic and I came up with 3.5" instead of 2.5" so I guess it's a bent fork.

 

damn..that sucks. might as well invest in the upgrade fork, T.O. bearing and fork plastic block, while in there. that trans will need divorced from motor And, if the input shaft has seen better days..(knarled up), you can install the FITZALL Input Shaft resleeve kit from ebay. Its what i did, and so far, seemed to have worked..(3+yrs)...good luck

INPUT SHAFT REPAIR KIT

 

It's already had a new clutch in it 2 years ago. And the input shaft was bad but I did but a bronze bushing in the flywheel instead of needle bearing but maybe I should look into that kit it still makes a little noise at times. Right now the clutch fork just broke and I'm stuck at work at a airbase on a flight line with no clutch this should be fun getting it home