Hello again, I have a 95 Ranger with 2.3 and 5 Sp manual trans. Last yr, the slave went out and I bought the ebay clutch kit. Yeah, I know. Sorta worked okay for a few days. Ebay seller replaced the slave cylinder for free. Would not change gears while running but it would change otherwise. It still would not change after the new slave. Bought a LUK slave and a pre-filled clutch master assembly after the second time taking trans out. Believe me, this system has been bled, burped and bled again. I took off the new pre-filled master assy just for good measure to tie it to a ladder to bleed it again. It has no air leaks. It has a new clutch, pp, pilot, on the third slave, all with the same results. This is the fourth time I will be taking it out.
I think it is time to look somewhere else. The original pilot was worn down to nothing, all the needles were gone and the only thing left was the outer race.. Well, it now has a new pilot which does have the same OD as the one that came off and it does fit the input shaft . The input shaft does seem to be out-of round at one spot. Could this be the problem? The shaft has very little or no play in and out. It has app. 3/16 play side to side.
Can someone explain to me when the input shaft is supposed to turn and not turn. Maybe, some troubleshooting test to try. I did jack the rear of the truck up tonight. The driveshaft will not turn with the truck in gear until the clutch is depressed. Isnt this telling me that the clutch is disengaging as it should?? I could actually see it through the access hole while my wife was pressing the clutch and daughter turning the tire.
Is the tail shaft supposed to turn as you turn the input shaft? A lot of questions, I know, but I need all the help with all probabilities this time. This is definitely the last time I am taking it out. Yeah...right

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1995 2WD Supercab, 5spd

I'll tell what I know, the input shaft only turns in the pilot bearing when the clutch is held down. If the input shaft has 3/16 or more side to side movement, when the clutch is released, it can drop down that much, causing a binding in the pilot bearing. You stated the input shaft seems to be out of round in one place, that could cause it to bind in the pilot bearing.

ThaForgot to mention that the truck does surge if it is left in gear while cranking with the clutch pedal all the way to the floor. This has been consistant every time I have tried anything new or different. I have seen all the perfection videos and everytime I do it, I do have 1/8 or less travel on the pushrod. As far as the slave bleeding, I have tried gravity bleeding dozens of times. I have tried bleeding it like brakes(pump,pump,hold,bleed,repeat) If I leave the trans in 4th gear and crank it, I can shift it out of 4th to N, I don't know what that is telling me. This is the only movement I can get with the shifter while it is runningnks tomboy.when I get it back out this week, I may need to look at that a little closer.

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1995 2WD Supercab, 5spd