hydraulic clutch - clutch won't disengage
This is killing me. 4 threads and 12 weeks and I still cannot drive the jeep because I cannot get the clutch to disengage. I am totally at a loss as to where I am going wrong.
3.7L 225 v6 oddfire and ford t18a transmission. New pilot bushing w/ oil wick, TO bearing, pressure plate, clutch disk, clutch fork, pivot ball, slave and master cyls.
The slave is from Novak with 3/4" bore and 2.5" stroke.
The master is wilwood and I have tried 2 versions, one with 3/4" bore and 1.4" stroke and one with 7/8" bore and 1.4" stroke.
No matter what I do, I only get 3/4" movement at the slave-clutch fork pushrod.
With the 3/4" bore MC, the pedal pressure is fairly even throughout and I get 3/4" travel at the slave pushrod for about 1" of travel at the MC pushrod. (Air?). To get more travel at the slave pushrod, I bumped up to a 7/8" bore MC because I really need 1.5-1.75" of travel at the slave cyl.
With the 7/8" bore MC, the clutch pedal is very soft for the first inch and there is NO movement at the slave-fork pushrod. Then, it gets noticeably harder to push and through the remaining pedal travel I get the 3/4" slave-fork pushrod travel.
Does this sound like air in the system? I have bled and bled and bled and there are no air bubbles in the fluid. I don't have any high points in the lines that might trap air either...the MC is the highest part of the system.
I am really at a loss. Air and more travel at the MC pushrod are the only things I can think of at this point. The clutch pedal is about 14" long with the pushrod being ~2.5" below the pivot.
Thanks for any help.