Hey guys! I blew my clutch (305K) so i replaced it with a 1200Lb HD Marlin kit from big country customs. When i was pulling the tranny out the clutch slave just fell apart and the piston popped out. the truck sat for about a week or so like that while i was ordering parts and did the rear main seal. Its a 93 with the 3VZE. I swear i put the release bearing and clip on properly. everything is put back together and i tried to use the old Clutch MC and flushed the system till the fluid was coming out clear. the clutch pedal went down with very little effort but stuck down and woudlnt come back up.... Replaced the Clutch MC. Had my cuzin come over to help bleed last night and we finished a litre bottle of brake fluid. Got lots of air but the pedal still has very little resistance behind it and still sticks to the ground. how much fluid should i be using to properly flush since the line sat open for so long....? Could my Mastyer cylinder be gone now too? im starting to second guess my release bearing install..or when i was installing the trans i mucked something up... I was reading something about pedal freeplay adjustment....could this be my problem after a new clutch install?

NOTE: there was a couple times my cuzin said he could feel alot more resistance but then after the next bleed sequence it went away. There does not appear to be any leaks anywhere but the original fluid was pretty dark and we got some nice rust chunks out of the line.

 

I had a similar problem when bleeding mine and it took alot to get the air out. Sounds like you got the air out on yours. There is also a spring attached to the clutch pedal to the crossbar under the dash. Is it still hooked up by chance?

 

I will have to take a peek at lunch. Its just so weird because there was so much resistance before the clutch went. It felt very tight with no freeplay.

 

Have your cousin check for any ballooning of the rubber clutch hydraulic hose when you push the pedal. Could be an aneurism style bubble causing your issue.

It was unclear to me if you replaced the slave...?

 

The slave was replaced. We flushed the system with the old slave and used 500mls. Replaced slave and used the last 500mls. No difference. Hoping the master isn't shot too. .

 

UPDATE: Pedal assembly and spring are looking good. My cuzin was the one doing the pedal pumping i was the monkey underneath. The pedal when i step on it now goes back up by itself yay! and there is alittle bit of resistance at the bottom of the pedal travel but i cannot get it to disengage enough to change gears. Do you guys think i should look into replacing the master cylinder or just get another bottle of DOT 3 and go to town?

 

replace both master and slave. Problem solved.

 

FYI: NAPA sells a DOT-4 brake fluid that is cheap & better than DOT-3.....

 

Bam! Couple more bleeds and there is enough movement of fork to change gears. 3/4" inch of movement. Problem now is it engages near bottom of pedal travel. Guess I got some freeplay to adjust. Thanks guys. Super nice just knowing there is support!

 

This new clutch is goona take abit to get used to, 300 more lbs of grabbing force..1200lbs total. Anyone else upgrade their clutch and notice a huge difference?

 

i have the 1200 pound clutch from marlin and i LOVE it. it grabs quickly and is easy on the leg and very very smooth