I see you did the same thing I did which is try to use the pushrod that came with the slave. That's not going to work unfortunately. Here's the thread showing pics of what I eventually ended up with and some attempts that worked, but weren't optimal:
It runs, but the clutch doesn't completely disengage
The problem is the slave just BARELY doesn't push out enough to completely disengage the clutch. What I did was replaced that green rod with a threaded rod from a carriage bolt. Then I used a series of nuts and washers to put a preload on the fork which is exactly what the old cable clutch setup did from what I've heard. That's been working for over 3 years no problem.
Also you'll need the quick disconnect piece from a stock Ranger center-mount slave cylinder to install in the slave. The stock Ranger hardline has a quick-disconnect piece on the end of it, not the piece needed to fit inside the slave. The quick-disconnect from the stock Ranger slave "converts" the quick disconnect to the fitting needed to fit inside that slave. Notice:
![Image](http://atlas.kennesaw.edu/~cgrey/ClutchSlavePics/ClutchForkThreadedRod.JPG)
You can see the white ring which is part of the stock Ranger hardline's quick disconnect fitting. The black part between that white ring and the slave is the piece you'll need installed if you don't already have it. This also shows the threaded rod I was describing above.
Also, no need to put any extra bracing on there to protect the bell. You can push that fork with the palm of your hand. It takes a little bit to do it and will leave red marks on your palm, but once it starts to move, it lets go and you can completely disengage the clutch with your hand. As thick as that aluminum is and as much torque as it is having to endure from the engine to the tanny, I seriously doubt the pressure from the slave will have any long term effect on the metal.
...Always Somethin'
89 Ranger Supercab, 331, ported GT40p heads w/1.6RRs, Crane Powermax 2020 cam, ported Explorer lower, FMS Explorer (GT40p) headers, aftermarket T5 'Z-Spec', 8.8" rear w/3.27s, Powertrax Locker, A9L w/Moates QuarterHorse, Innovate LC-1, James Duff traction bars, iDelta DC Fan controller
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