I just replaced the transmission, clutch assembly, Flywheel turned, slave assembly is new, and had the transfer case rebuilt in my 94 Explorer. I now get a slight shudder when I engage the clutch. Also the clutch pedal seems to be all the way up to the top for engagement now. Has anyone ever had a problem similar to this, and what could be causing it?

 

Generally, the shudder you described is a common symptom of when the clutch system is worn out. Since your components are new, this should not be the case.
The shudder is due to a catch/slip/catch/slip in the clutch system. Usually caused by inadequate pressure plate to clutch to flywheel engagement caused by a worn out clutch disk, broken shock springs in the clutch disk, low spring pressure in the pressure plate, or all of the above. It can also be caused by oil on the surfaces of the clutch system from a leaking rear main seal, or a slighty "bent" clutch plate.
I have seen clutch plates get bent during installation when the transmission is installed. It happens if the transmission is not properly supported and aligned.
Check your pedal travel problem first and see if that is the cause of the shudder. If you are not releasing the pressure plate all the way, it will cause the shudder you noticed simular to a weak pressure plate. The system is all hydraulic with the slave release cylinder inside the transmission bell housing. I do not see any adjustments that can be done. It is possible that you have some air trapped in the system, so bleed the system one more time. Bleeder valve is down on the transmission bell housing adjacent to where lines connect to slave cylinder.
Dilatone

 

I have a 91 5speed. I bought it 4 years ago with 121K. Soon after, I replaced the clutch and pressure plate, along with some other maintenance. It has always had some shudder, especially when hot.

Since then, I have replaced both the master and slave clutch cylinders, a defective pilot bearing and release bearing(came with the slave cylinder). My problem is not too serious, once you get used to it. I have learned how to release it most of the time without the shudder.

I suspect the main cause is in the rebuilt pressure plate. Don't have any proof to offer, but it's just a gut feeling I have.

I thought about replacing the engine mounts, but that's just too much work for an experiment.

I am curious, though about your clutch being at the top. Mine has always been at the floor, too close, acutally for comfort. In fact, there is a bolt which came through the firewall which the pedal hit if pressed far enough to release the clutch fully. I removed it and cut it off short enough that it just comes trough the nut. Now I can push the pedal to the floor without interference. This condition did not change when I replaced the cylinders.

I believe if you had air in the system you would have the pedal too low, like mine, not too high. With air in the system, you have to push the pedal farther - like when you have air in the brakes.

Anyway, I have just lived with my situtation, and now soon approaching 193K miles.


Winford