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I own a 2001 4x4 with the 4.2 and a 5speed manual tranny. I'm nearing 55k miles, ever since the weather has begun to cool down I have encountered a problem when I cold start my vehicle. I'm unable to shift out of gear, if I leave the vehicle parked in Neutral I can't shift it in to gear. However if the vehicle has been ran that day I can hop right in with no issue whatsoever, but if it sits for a day It still sticks in gear. I have noticed after driving the truck for a mile or two, it operates as good as new with no issues. I'm suspecting a bad throwout bearing due to the fact that I have to top off the clutch fluid reservoir every week. However, there is no chatter when I depress the clutch, I'm sort of stumped on what this problem could be. Any suggestions?
I'm hoping it's not a faulty throwout bearing, dropping the transmission for a $5 part is pretty lame, haha.
Sounds like a leaking slave cylinder. It's getting air in the system.
When it's cold, try pumping the clutch pedal several times, then try putting it in gear. If that works, then it's getting air in it.
I have also found that if you changed you tranny with a poor grade oil that it does not perform well in cold temperatures. I was having similar problems, changed to Royal Purple synthetic and problem solved. It is considerably more expensive than the cheap oils at the autoparts store but it is definately better.
The seals on the slave cylinder were blown out. I found a new clutch kit for $300. This disappoints me, my 1995 F150 had 155k miles on it with the factory clutch. When I traded it in for this new truck the only issue I had was the throwout bearing was starting to go bad and chattered. Seems a lot of people have had issues blowing seals on their slave cylinder when the weather cools down in the 2000-2003 trucks and it always happens after the warranty is gone.
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