I have come seeking help with an issue I,m having with my 91 Ranger and I do apologize for my very first post on this great site being a tech question. Here goes; The clutch slave cylinder was leaking so I go to NAPA and get a replacement. I get it installed and reinstall the transmission only to find the hydraulic line will not snap into the slave and I tried until I ruined the male end of the hydraulic line. Upon further research of the NAPA slave part number I discover the slave is actually for a 93 model Ranger. In avoidance of removing the transmission a second time and due to the fact I need a new hydraulic line I present these questions to you; Will a clutch hydraulic line for a 93 install on my 91 and will the 93 line work with my 91 clutch master cylinder? Thanks!!! and Thanks for a Great Site!!!!

 

Welcome to the forum

Yes, this is actually a common issue in that Ford changed the style of the clutch line "Quick Connect" on Rangers in the early 1990s.
But it was not Year specific, it spanned 2 or 3 years as Ranger assembly plants got the newer versions and didn't start to install them until older versions they had were used up.

A new Master should come with correct Quick connect, but have parts store pull out another of the Slave they sold you and the new master then you can compare the fittings.

The new master will fit your model year
I don't recommend just trying to replace the hydraulic hose, even if you can find one, hard to get a good connection to master

 

Sounds like a plan! Thanks RonD!!!

 

Ok, so I now have a 93 slave and master cylinder assembly installed into my 91. I had to use the angle grinder in the area surrounding the master cylinder at its mounting point on the engine bay side to remove some pinch weld material to allow the master cylinder mounting flange to seat flush against the firewall. My new problem is I cannot get the clutch pedal rod that came with the master assembly to slip inside the master cylinder. It looks like it needs to slip in an inch or so and lock into place. It will not and the truck will not start because the travel is not enough for the safety switch to make contact. Is it recommended that I remove some material from the clutch rod tip that contacts the master cylinder or did NAPA include the wrong rod with the master cylinder assembly? Thanks!!!

 

That is odd, the push rod should come attached to new master, they are in fact hard to get off the master if you ever need to

There is a one-way clip on the master that the rod slips into when it is assembled, so it can't pull it off

Try forcing rod down, but I assume the clutch pedal would do that the first time you used it

Never ran into that problem, taking rod off yes, but never tried to put it back on

 

I knew it had to be a rare instance because the only mentioning of the clutch push rod on the web involved problems removing it and not installing. I have the clutch push rod in the freezer for now and I'm going to try to get it in later today. If at that point I'm still unable to get the rod into the clutch master cylinder I will then take some metal off the tip. Honestly, I used to have a lot of faith in NAPA counter salesmen/saleswomen and in NAPA parts but my faith in the organization has diminished with this project.

 

Honestly, after the amount of issues that I’ve read on here and other places with the slave and master cylinders on these rangers..I personally would only purchase the Motorcraft replacements..........

 

After all the trouble I have recently had I too will recommend Motorcraft. It is a lesson that was well learned!!! I did finally get the NAPA parts together but only after taking some metal off the clutch push rod tip.