Engine/Transmission (1998.5 - 2002) Hydraulic Clutch Assembly

[Augustus]

Alright, I am on my fourth hydraulic clutch assembly, what is going on? Anyone else have these problems? Is there a trick to installing these things? This is ridiculous. Granted the first one was under warranty and the rest have not cost anything, but this is nuts.

 

[South Bend Clutch]

Augustus,



When you say "fourth hydraulic clutch assembly" are you just refering to the hydraulics or everything, clutch assy. and hydraulics?



Peter

 

[MikeR]

Do you have an upgraded clutch in your truck? If so, which brand/model clutch? Do you keep having the same component fail? Which component in the system?



-Mike

 

[Augustus]

The hydraulic cylinder and the line to the throughout bearing, that's it. The one piece unit. I do not have an upgraded clutch. It seems to go for about six months, and then all of a sudden it fails, clutch pedal goes to the floor with no pressure. The piston that connects to the clutch pedal seems to develop a leak and then it's gone. I don't get it.

 

[Turbo Trucker]

I never had any problem with mine.

 

[rickhans]

Are you talking about the master or slave cylinder. There was a posting last year about problems with the slave cylinder but I don't remember what it was. I do remember, however, that more than one member had purchased a replacement cylinder from NAPA and listed the NAPA part number, and had good results. A side product of putting the NAPA part in was reduced pedal pressure because it had a cylinder that was double the diameter of the Dodge slave cylinder.



You might try searching on NAPA although you will probably get a lot of filter postings. Also try SLAVE.

 

[MikeR]

I was the one who discovered the bigger slave cylinder, but it will not work on stock clutches... only on higher pressure aftermarket clutches. The pressure will be too low.

You can, however, purchase a stock-sized slave cylinder from Napa. They do exist.



But I do not think the clutch hydraulics is your persistent problem. Something about your clutch is destroying your hydraulic system.

 

[John Berger]

Hey Mike, do you have the part number handy and if you do could you post it. TIA



John

 

[Augustus]

What about my clutch could be destroying the hydraulic system?

 

[redram]

Originally posted by Augustus

The hydraulic cylinder and the line to the throughout bearing, that's it. The one piece unit. I do not have an upgraded clutch. It seems to go for about six months, and then all of a sudden it fails, clutch pedal goes to the floor with no pressure. The piston that connects to the clutch pedal seems to develop a leak and then it's gone. I don't get it.

You haven't given us much to help you with. What happens when it "fails"? Does it leak fluid? Is the tubing failing?



325,000 on two trucks without having to replace the clutch, clutch slave, clutch master cylinder. Did have a problem with a fitting on my 89 truck that began to leak due to a worn keeper pin (non stainless) that wore down allowing the line fitting to move in the slave cylinder bore allowing it to seep fluid under pressure.



Augustas, what's failing that keeps needing replacement? These systems are farely reliable. Type of clutch should have little bearing on the clutch slave unless you have a monster clutch with huge pedal force effort.



Remember, hydraulic pressure is hydraulic pressure.

 

[Augustus]

The slave cylinder starts leaking fluid. Could be a bad gasket, maybe the rod is not lined up correctly and it finally wears a gasket out?? I have the stock clutch in my truck.

 

[redram]

Does the slave leak from the piston seal bore or from where the fluid line fitting attaches to the slave cylinder body?



I had the second happen. The fitting uses an o-ring seal and is held in place by a roll pin. On my '89, the roll pin was not hardened. The pressure of depressing the clutch would try and push the line fitting against the non-hardened roll pin causing it to wear. When the roll pin wore enough, the o-ring on the fitting would not seal. I replaced the non-hardened roll pin with a stainless one and problem was solved.



Don't know if this is anything similar to your situation but that was what I found many years ago, at least 9.



Maybe this will give you something to look for.



Good luck.



Redram.