Clutch Slave Popping Off - My easy fix - Ford Powerstroke Diesel Forum
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Old 10-08-2006, 07:47 PM
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Clutch Slave Popping Off - My easy fix

Some of you read my first posts a little over a month ago when I bought my '96 F-250. I had to replace the clutch slave cylinder & master cylinder. What sounded like a horrible job, turned out to be REALLY easy. The parts cost me $99.94 at O'Reilly Auto Parts for both the clutch master cylinder and the clutch slave cylinder.

Now, everything went ok, took about 30 minutes to do both, and bleed the system. I probably put about 3,000 miles on the truck since then and out of nowhere one day last week the clutch slave cylinder fell off the transmission while I was driving. I pulled over and crawled underneath to find it hanging from the line. Turns out, the crappy design of the slave cylinder mounting clamp was the problem. I popped it back on the trans and everything seemed fine for a few miles...Well, it happened again, and again, and another 3 times before I finally got back to work. After work I crawled underneat the truck with a cordless drill and drilled a 5/16" hole through the slave cylinder mounting bracket, and right through the aluminum mounting tab on the transmission bellhousing. Then I popped in a stainless steel bolt, flat washer, and lock washer and nylock nut. No problems since then. I'll try and get a picture of it and post it up if anyone needsa visual.

So...not sure if this is something that happens with these slaves often, but just incase it does, or just incase you want to prevent it from happening...it took me about 3 minutes to drill the hole & install the bolt. Easy insurance that it won't happen again. (Be sure to use stainless steel, if you have to ask why...well...nevermind)
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