1994 Mazda B2300 2.3 4cyl.
My clutch was beginning to slip really bad, so yesterday, we replaced the pressure plate and clutch disc. We did this by removing the center crossmember holding the trans in place, unbolting the trans, and while jacked up, sliding it back off the flywheel/motor just enough to access the pressure plate and clutch disc. No hydrolic lines were disconnected at all, just the elctronic plug at the top of the trans from the main engine harness. Everything else stayed in place and moved slightly back with the transmission.
We replaced the pressure plate and clutch, centered the disc in the process, slid tranny back into place (went together easily), and then bolted everything back up. Put the shifter back on and it when the truck was off, it shifted in and out of the gears smooth. BUT....no pedal pressure.
We took off the inspection window rubber on the trans and watched the throwout bearing as we pumped the pedal and it very very slightly moved, but not enough to disengage the clutch....it just barely moved.
So then we began trying to bleed the system...which after researching online, I found out is the biggest pain in the ass ever! LOL.
Apparently the rangers & explorers have a really hard system to bleed due to the "quick-disconnect on the slave cylinder, the fact that it has an internal slave cylinder in the trans, and the master cylinder is basically inverted on the firewall.
We tried gravity bleeding for hours and hours, but this never seemed to work. Thought we had a little bit of pressure at the pedal for a minute, but if we ever did, it faded away when we began bleeding it more.
I basically tried everything, then even took it to a local shop that had a pressure bleeder. They tried to pressure bleed it for two hours, called me up, and said "come get your truck...we aren't going to charge you anything because we couldn't fix the problem." Still no pedal pressure.
When I was looking around online, people were saying to do everything you could possibly think of, including completely removing the slave, master, and reservoir, bleeding seperate from the truck, and then re-installing it already pressurized. Some were unbolting the master cylinder from the firewall and flipping it upside down, some were cracking the quick disconnect to release air rather then using the bleeder on the slave... everything you could think of.
I was hesitant to try all this stuff because half of the forums where people had posted these ideas, they received responses back saying that this way didn't work for other people!?!?!?!?
I'm about stumped now...maybe when we pulled the tranny back, we created a leak somewhere? But we've been looking the lines up and down and cant find a leak anywhere. Maybe we tweaked the slave cylinder connection when we backed the trans up off the flywheel?
I don't know where to begin at this point, but would love some direction/helpful hints/top secret info from anyone who has done this nasty task?!?!?!? I really don't want to replace the whole damn system if I don't have to...lol.
A big thank you for any feedback/info beforehand...it is much appreciated. Thanks guys!!!!!!!!!!!