was the spacer like an inch long and an inch wide or so and hollow and silver? if so i was trying to figure out what that was. im going to get a new slave cylinder tomorrow. the thing that confuses me is i can shift through gears like the clutch is engaged, but at the same time when i put it into gear the output shaft spins so the clutch must be grabbing somewhat id assume

 

it was about 1/2 inch thick and just big enouff to slide under the ball on the clutch fork just wondering you didn't pinch the clutch disk between the pressusr plate?? one of my friends did that on his j10 but i dont think he could get it into gear at all... just a thought there isn't anyway that air could have got into the slave cylinder is there or now here's a good one the shaft on the slave cylinder couldn't have paped out of it's hole and is riding on the edge of the piston in the slave cylinder, grab the end of the shaft and wiggle it around some see if that helps at all. I don't know if any of this will help but i'll keep tryen to think of ideas to bounce off ya.....good luck buddy

 

on old style truck clutches they use to block the pressure plate springs would keep it from releasing but upon installation would fallout yours didnt have something like this and maybe got hung up to keep clutch from engaging all the way

 

Put your transfer case back on and hook up the rear driveshaft, being able to shift through all your gears with no clutch is perfectly normal when it's not running. When your output shaft is freewheeling because the driveshaft isnt hooked up, your synchro's will bring the internals up to speed by themselves allowing you to shift it easily without the clutch when it is running. Without something holding the output shaft still, theres not really any way to see if the clutch is functioning properly.

 

after the end of my testing yesterday i notived the slave cylinder was leaking its toast so i just got back from driving into town ill put the new one in tomorrow hopefully thatll help my soft pedal problem (im sure it will)

i talked to jason at diesel nut motorsports and he said the exact same thing. im going to try and get the transfer case in tomorrow but cant guarantee it as im by myself and these things are heavy as we all know. but ill try and get it back together and ill keep you guys updated. thanks everyone for the help!

 

Re the shut off solenoid the plunger has a rubber tip that closes off the port to the high psi chamber on the VE. As the pressure drops the injectors close. That leaves fuel in the system. When you re-start the truck pressure builds up and opens injectors in firing order sequence. What usually happens is that the rubber tip on the solenoid comes apart that allows fuel to keep flowing into the HP side of the pump.

Re your trans. the trans can shift without the clutch under several conditions' 1 when the truck is not running and 2 when there is no load on the drive line. I am willing to bet that when you hook everything up it will not have this problem. What you might find the it will not shift into any gear or it will work just fine. If it does not shift my vote would go to hydraulics - clutch master/slave setup.

If you decide to re-install the drive line from trans back and it will not go into gear post - I have a solution for that.

Bob

 

also by just taking the fuse outa the air dog doens't mean the motor isn't getting fuel. I noticed once of my fueses blew on my air dog after about 2 days cause she was having a hard time starting but would run just fine. So the truck will still get fuel, the air dog just makes sure it stay's at a constant psi.

 

i wasnt pulling the fuse i was unplugging it completely but i got that situation all worked out

well heres an update. got the transfer case on, a new slave cylinder and bled it all out. i have a hard pedal now at least. so i went to put my dirvelines in and both of them are too short but when the truck is running, if its in neutral (no drivelines) the output on the transfer case spins very slowly and when i put it into gear, it starts spinning faster like it should. is this normal? but it is still very easy to put into gear and doesnt require a clutch. i gotta wait to get drivelines in to tell for sure but thats where im at.

 

thats normal,but what are you doing with you r drive shafts?why r they different now?wtf

 

because a manual trans is approximately 8" shorter than an auto trans with overdrive