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I have a '96 F150 with the 4.9, I6, 5 speed manual transmission, 2 wheel drive.. The problem is when the weather like today reaches 10F or below. The clutch is hard to depress and appears to be losing fluid. The clutch doesn't disengage properly and I have to add fluid to the master cylinder. Is this a common problem in the cold? Is there something I can do to correct this?. It only happens when it is wicked cold but January in Maine always is.
Its gonna be hard, just because of the cold, but.. the fact your loosing fluid isnt a good sign, i would start looking for drips or wet spots to see where the fluid is comming from, it could be the slave cylinder, (on or in the belhousing) maby the master cylinder, or the line. and the reason it isnt disengaging is because it has a loss of line pressure, wich makes it start to close as your holding down the pedal, therfore engaging the clutch slowly, I would start looking for leaks, thats probly the problem.
Bleed your system and fix the leak. You may have to rebuild your master or slave cylinder, but try bleeding first and replacing fluid. You may be able to look into the area where the shift fork runs on the pilot shaft and it may have gummed up on the shaft and the cold may affect the operation's smoothness. Good luck.
Tex
if you got a 96,the slave is inside the bell,there is no sense rebuilding it,buy a new one and replace it,which involves removing the trans,while you are there,replace the clutch also.cheap insurance.
i have the same problem with the cold clutch problem,but mine has over 160,000 on it,origional clutch,cold leak,warm no problem.a slave will run you about $70.the time it takes to replace is about 6hrs total.
My 95 clutch completely failed during some cold weather last year. You’re not going to like hearing this, but if you have it done by a shop it will cost a bundle. You do have to take the transmission and in my case the transfer case out. Once you’re in there you might as well put in a new clutch and resurface the flywheel. Mine cost about $1,000 for everything. That plastic slave cylinder inside the transmission is a stupid, stupid design!
Doesn't sound like a job I want to do in the driveway, not with 2 feet of snow, 30 mph winds and a high today of 6F. I will drop it by the shop Monday and take my lumps.
i had a friend who had his done at a trans shop a few yrs ago.labor was $250,parts was about $200.we had a new clutch,throwout/slave,plus master cylinder also.
not a job in the driveway.transfer case comes off,then the trans comes out.the fun part is getting the hydraulic line off the slave.sometimes there a pain.ive done 3 so far,going to do #4  soon.got a truck with a brand new remand motor,clutch,and slave in it for free.friend wanted to get rid of it.
Thanks guys you were all correct. It was the slave cylinder, it's internal and it cost a bundle. Ran me $650 with a new clutch. Can't complain this is the first non-maintance repair I ever had to do. Not too bad for an 8 year old truck with close to 100,000 miles. Oh wait, the turn signal blinker failed a couple years ago, $2
I have done two clutches in these trucks so far. One was in my heated shop on the lift the other was in a driveway. It wasn't really that hard. the thing you have to do to get the clutch hose out is use two small flat screwdrivers and push the little white plastic clip inside the hose to release the hose. make sure that is about the first thing you do so you don't try to yank the tranny out with this still hooked up. if you have someone helping you and they said it was out double check. I took someones word for it and i had to replace the clutch master cylinder also. lesson learned.