Working on a 93 T100, 3.0L, 5 spd. 4x4. Doesn't shift worth S*&t, won't go into first w/ engine running. Just bought the truck a week ago, ran fine, shifted fine. Shift brackets look okay, didn't see any cracks/ bending etc.

I am sure that it isn't getting the clutch fully disengaged (reverse grinds bad etc.). How far is the clutch fork supposed to move? Mine is moving about 3/8".

Also, pretty sure the rear main is leaking, but would like to put that off for a bit.

 

Oil leaks are usually from the valve cover gaskets...look at the back of them.

The clutch bracket is the first suspect...really. Especially the first year (1993). What color is the bracket? If it's bare metal, it's the first OEM version. If it's black, then it's probably the replacement one.

If the bracket is the right color, then next on the list would be the clutch master/slave units. Might need a bleeding or just rebuild/replacement. You got someone to help you with the bleeding?

 

Yeah, the valve cover gaskets are leaking, gonna get to that but need it to run for a bit. The clutch bracket is bare metal, so first gen. The slave cyl is painted black - assume it is a replacement.

Before I go swinging parts, do you know how far the slave is supposed to push the fork lever?

Thanks!

 

Okay, started swinging parts - replaced the master cylinder. When putting the new one on, I noticed the firewall was cracked.....WTF? Even so, the clutch lever seemed to be pushing in the master push rod about 3/4" yet, the slave is only traveling 3/8" or less. I pulled the slave out, it was free to travel and didn't hang up and isn't leaking. I check the lines, no leaks, checked the flex hose, no bulges or leaks. Went through about a quart of DOT 3 bleeding the damn thing, no joy. Thoughts?

 

The clutch pedal bracket is definitely cracked...and since it wasn't replaced when the symptoms started showing itself, it stressed and cracked the firewall. It's a common problem on the T-100s with the manual transmission.

From 4x4Wire forums...

 

BTW...yer gonna need to have that firewall welded up before you put them new brackets on.