Truck Trend Garage: Grinding Clutch Woes on a 1994 Ford Explorer

Q: I recently had the clutch replaced on my 1994 Ford Explorer with the 4.0L V-6 at 92,000 miles. I was having problems getting the transmission into gear, and it would grind going into reverse. They replaced the clutch disc, pressure plate, release bearing, and pilot bearing, and they resurfaced the flywheel. It was okay for a while, but I started having the same problem three- or four-thousand miles later. This time they bled the hydraulic system, and it seems alright again. Did I really need the clutch job or would bleeding have fixed it the first time?   |   07z 1994 Ford Explorer A: The high mileage indicates it was probably significantly worn. The problem now is the fact that bleeding the system with no additional repair work may have corrected a symptom but not the cause. This means the leak that allowed air into the hydraulic clutch system on your SUV is still there and the grinding gear scenario will return shortly. The hydraulic clutch system eliminates the cable and linkage between the pedal and clutch with a setup just like your brakes. The pedal pushes on a master cylinder with a reservoir full of brake fluid. The master then transmits hydraulic pressure through high-pressure tubing down to the slave cylinder, which disengages the clutch at the transmission. Get your Explorer back to the shop and ask them to thoroughly inspect the entire system for any signs of a fluid leak. The most common weak link is going to be the slave cylinder, and it can be tough to spot that leak. There's an improved design clutch-slave cylinder from Ford (part #F87Z-7A508-AA) that should prevent it from happening again if that's the case. How To Reach Alex
If you have a technical question regarding your pickup, SUV, or van, feel free to contact Alex, a master technician with the National Institute for Automotive Service Excellence. Send a letter to him in care of Truck Trend Garage, 831 S. Douglas Street, El Segundo, CA 90245, or e-mail us at trucktrend@sourceinterlink.com. Please include the VIN with your question. Due to the volume of questions received every month, we cannot guarantee that everyone's question will be personally answered or will appear in the magazine.

Can't wait for help with a problem you're having with your Truck or SUV? Ask the expert we trust here at Truck Trend Garage—visit Alex Steele at www.RealWorldAutomotive.com.