I have a 1995 F150 4x4 with the m5r2 transmission. This weekend I replaced the original m5 with a fresh rebuild. I did this because the original one had lost all forward gears, before that happened it was acting as if the clutch wasn't fully disengaging, this is after getting a new clutch system, everything but the peddle was replaced.

Now with the new transmission in, I am getting the same feeling, as if the clutch isn't fully disengaging, I have bleed the system and can see the slave pushing the fingers on the clutch in when the peddle is pressed, but still will not slip into gear as it should. I have re-replaced everything but the slave and the clutch pack at this point, the slave and line had to be replaced soon after the original clutch (the next day) job do to the fact that O'reilly's sold me the wrong slave and clutch line, and several other parts as well. Now I am down to only the clutch pack having come from them. After a process of elimination, and many hours on the net checking pics and videos to try and get an idea of what may be my issue, I am down to the clutch pack its self being incorrect some how. I am going to be pulling the clutch pack and replacing it with a Napa clutch pack today, Napa seems to be able to get the the correct part every time so far with this truck. Part store rant aside, has any one else had issues of this kind with their truck?

Thanks for your time and any incite that you can offer.

 

i think firewall flex was eliminated by 1995 ... someone will surely correct me if I am wrong, but have you eliminated worn clutch pedal bushing(s) as the culprit ?

 

you need to replace the slave cylinder and crawl under the dash and look at the pedal bushing to see if its worn out. and also check the pedal spring as well

 

I have not checked those bushings but will now, another idea that was suggested was a flywheel that was to thin.

Thanks for the places to look.