Wow. Talk about a headache and a half. My clutch finally went out on My 05 4.0. I ordered some parts. Received a week late seeing they were the wrong ones. Sent back. Ordered new parts a week later they show up. Get everything installed pretty easy. After some troubleshooting I see it’s the incorrect slave. I buy the right one from the orileys. I bleed the entire system both bench and gravity bleed. Still has to much play. Any advice?

 

With the pedal pushed fully to the floor, is there any trouble getting it into 1'st or reverse ?

And did you use a self adjusting clutch ?

 

Not sure if it’s self adjusting. It is hard getting it into gear.

 

Self adjusting pressure plate will have 3 or 4 extra springs around the pressure plates forks, seen here: http://cdn.nexternal.com/uuc/images/CLUTCH_LUK_SAC.jpg

Regular pressure plate has no springs, looks like this: https://spareto.com/system/products/...png?1540741539

When slave cylinders were external there was need for self adjustment since you could adjust clutch pedal travel externally
With the advent of internal slave cylinders there was no way to adjust pedal travel, so SAC(self adjusting clutch) was used

Regular pressure plates will work fine, but....................when clutch disc is NEW, and thick, clutch pedal will have to be push down all the way to the floor(and an inch more, lol) to disengage the clutch disc fully
It WILL GET BETTER over time as the clutch disc wears down a bit, maybe a few weeks depending on how much you drive it, the more the better

The SAC pressure plate changes position over time as the clutch disc wears down, so clutch disengage and engage happens in the middle of pedal travel until its time for a new disc, SAC pressure plates can be reused but MUST BE RESET using hydraulic jack/press

You could have air in the system, air limits the full travel of the slave so clutch disc is not fully disengaged