Ford Repair: Clutch Problems, cross shaft, clutch problems


Question
Problem started with hard shifting and grinding.  Tried bleeding the slave, no improvement.  Replaced Master - no improvement.  Machined flywheel, replaced clutch, and slave - there is some pedal (the last 2 inches) hard shifts into all gears but no reverse.  Lost cluch pressure (even after bleeding and no bubbles appeared) thought the Master might be defective, replaced it again - no improvement, thought the slave might be defective, replaced it again - some pedal (free play on the pedal for the first 2 to 3 inches) and hard shifting but no reverse.  Lost clutch pressure - bleeding shows bubbles after having previously bled with no bubbles.  1993 Ford Explorer 2WD 5 speed -HELP!

Answer
Hello and thanks for the question...I'll try to help.
 Let's start at the beginning. Completely drain the fluid from the system. Then, close the bleeder and fill the master cylinder. The have a helper pump the clutch pedal 30 times and hold it to the floor. Open the slave cylinder and allow the air/fluid to come out. Close the bleeder at the slave cylinder. Then repeat this 5 more times, filling the master cylinder each time. You should have a pedal now. Another thing you might want to check is, to make sure you do not have ANY fluid leaks. One last thing, go under the dash and check the clutch cross shaft and bushings for wear. There should be no "slop" in the cross shaft. Also, check to make sure that the fire wall where the master cylinder is mounted is NOT cracked. You will notice the fire wall flexing when the pedal is depressed. If this is the case, stop there and ask Ford if there is a repair kit for this problem. I think there is, but not sure. I do know they had problems with the F150-350 series on this.
Hope this helps,
Erik