Hi, I have a 92 flare side 4x4 with a 302 wth 5spd. I have just installed a new clutch/pressure plate, throw out bearing and slave cylinder assembly and a new master cylinder for the slave. problem I am having is the clutch is at the very bottom of the pedal, like the first 1/2" its engaging. I have bleed the system and there is no air in it. the pedal is firm all the way down. has anyone else encountered this before? almost wondered if I put the clutch plate in backwards but not wanting to drop tranny unless I have too. Thanks

 

You have (one or more of)

• A torn firewall where the master bolts on.
• Clutch pedal that is not allowing the Master to completely release, Ensure there is a tiny bit of play on the push rod between Master and Clutch Lever.
• Master Push Rod bushing failure or improper installation
• Failing/Failed Master
• Failing/Failed Slave
• Air in the System
• Broke Bell housing
• Damaged or Improperly installed Throw out fork or pivot
• Improperly installed or wrong Throw out Bearing
• Improperly installed or wrong Pressure Plate
• Improperly installed (backwards) or wrong Clutch disk!

Do this, Motor off, Parking brake on, Wheels chocked, Get a helper, Grab a measuring device crawl under the truck and measure the stroke of the Slave cylinder as your helper pushes the clutch all the way to the floor.

Post the result!

-Enjoy
fh : )_~

 

No throwout fork or pivot in a Windsor.
The slave cylinder is internal and concentric to the transmission input shaft, so it would be very hard to measure how much it's moving.

Did you bench bleed the MC first?
These clutches can be very difficult to get the air out.
If you have enough pedal to get it to disengage you might try just driving it.
Often bouncing down the road will get the bubbles to rise out of the system.

 

Yup, My bad ...

-Enjoy
fh : )_~