Sorry to say this isn"t just a Ford problem, we had the same problem with a "98 S-10 and a "00 Silverado. We replaced both of them ourselves, there were no leaks, and replacing the master cylinder first did not help. On the Silverado we did the master cylinder first, no luck, so we replaced everything else(Pressure plate, clutch disk, slave cylinder) and it was ok, but to look at anything you would say it all looks good. On the S-10 the clutch was shot, so we replaced the disk and pressure plate, six months later we replaced the master cylinder, still would not release so we had to do the slave cylinder. Also a friend of mine with a F-350 PS, had his clutch quit releasing, he replaced everything and now it works, but to look at the parts you would say everything looks good.
I talked to an engineer at a major producer of clutches in the US, we couldn"t come to reasonable explanation.
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