Working on my Nephew's 91 ranger, we just put in a new clutch kit and a new master cylinder but still could not put the trans in gear when running. Upon looking closer my nephew noticed the whole master cylinder moving when I pushed in the clutch. Investigating further the firewall is cracked about 3/4 of the way around the unit. The master cylinder is probably permanently pushed in 1/4 inch and will travel another 1/2 inch when the pedal is pushed.

Has anyone else had this problem? Any suggestions on how to fix?

 

grind the paint off & weld a plate of metal to it, you gota turn the heat down cause if not you will burn threw the firewall its not to thick

 

this is very common on 1st and 2nd gen rangers. if you weld a plate over it the master will not twist and lock on. you will need to cut it out and trace the opening on a piece of sheet metal and weld or bolt it in the same place

 

Thanks for the info. I also have a 91 with manual, is there anything that can be done to prevent this problem before it shows up?

 

Thanks for the info. I also have a 91 with manual, is there anything that can be done to prevent this problem before it shows up?

 

make sure you catch the rust before its to that point