Clutch Master Cylinder Rod Bushing Replacement? - Ford Powerstroke Diesel Forum
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Old 10-21-2013, 06:37 PM
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Clutch Master Cylinder Rod Bushing Replacement?

I am looking to replace the plastic bushing that is known to wear out in my 5 speed. How do i go about doing so? Thanks
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Old 10-21-2013, 08:11 PM
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Do you mean you want to replace it with something better? Two options:
* Cut off the eyelet and replace with a Heim joint. There's a guy on eBay selling them, but it's just a generic joint like what you can get at McMaster-Carr, et al, re-packaged and up-priced.
* Get some 1/2"OD x 7/16"ID brass tubing, cut off just a short piece (just enough to fit in the eyelet. Then install in place of the cr@ptastic plastic bushing, and put a 7/16" drill stop collar on the end of the stud that goes through the eyelet. Result looks like this (thumbnail is link):

If the bushing is so shot that the eyelet is worn, i.e. ovalized or "egged", the brass tubing fix probably won't work, and you'll either have to replace the pushrod or opt for the heim joint fix.
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Old 10-21-2013, 08:13 PM
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Do you mean you want to replace it with something better? Two options:
* Cut off the eyelet and replace with a Heim joint. There's a guy on eBay selling them, but it's just a generic joint like what you can get at McMaster-Carr, et al, re-packaged and up-priced.
* Get some 1/2"OD x 7/16"ID brass tubing, cut off just a short piece (just enough to fit in the eyelet). Then install in place of the plastic bushing, and put a 7/16" drill stop collar on the end of the stud that goes through the eyelet. Result looks like this (thumbnail is link):

If the bushing is so shot that the eyelet is worn, i.e. ovalized or "egged", the brass tubing fix probably won't work, and you'll either have to replace the pushrod or opt for the heim joint fix.
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Old 10-24-2013, 04:34 PM
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Okay thanks, but how Do i go about replacing it? Do I pull out the master cyl on the fire wall or can I access this from where the clutch pedal is?
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Old 10-24-2013, 04:48 PM
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If you're doing the cheapo mod with the brass tubing and the drill stop collar, you do that with the master cylinder in place.

If you have to cut off the eyelet and do the Heim joint, you _might_ get away with doing it in place, but it'd be a lot easier removing it and putting the m/c in a vise. Technically, there's a c-clip way into the M/C that you can use to remove the pushrod, but it's a PITA to reach. If you opt to do this, you might consider removing the whole hydraulic system as an assembly, and keeping it upright (master above the slave) for the whole time. You might avoid having to refill and bleed it (another PITA job) that way.
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