Urgent Help Needed!! New clutch trouble - Ford Powerstroke Diesel Forum
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Old 09-24-2007, 03:09 AM
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Urgent Help Needed!! New clutch trouble

Hi everybody - I have a truck that is used on the Fire Department and I need some Help! Last night I replaced the clutch because the old one was cooked. R & R wasn't to bad, got it all back together and ..... the clutch wo0nt release from the trans. Here is the detials that might help solve this:

Old clutch although worn released RIGHT OFF the floor - I mean really right off the floor.

Freeplay in the clutch pedal is about Half the stroke distance, followed by a stiffer pedal than before

The clutch kit was an OE style, valerao (I know I didnt spelt that right)

Replaced the throwout bushing and the input lil bearing on the flywheel


Now- I am a fairly good mechanic but am not the vet ford diesel man that I would like to be. My friend works on these all the time and he told me that he would check the pedal bushing that snaps into the aluminum rod that goes thru the firewall. I did, and the bushing was toast. As a quick fix to try and ban-aid it, I took electric tape and wrapped it around the metal stub and then jammed it onto the aluminum hole on the pushrod. There seems to be play in that whole assembly, the fake bushing helped but didn't fix the problem.

So My questions are:

What the heck is wrong?

Do I have the wrong pressure plate (they looked the same - but the new one didnt have the holes for the alinment dowels, so we drilled it out by setting the old atop the new and marking - the holes were right on and the clutch bolted right up)

Do I have a bad slave cylinder that was marginal before and now doesn't have the stroke needed for the new non-worn thicker clutch?

Do I need to bleed it for some odd reason?

Thanks in advance- I really need to put this truck back in service ASAP!!

Pete from Maine
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Old 09-24-2007, 03:11 AM
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Oh yea- my opinion - It really seems that I have a stroke depth problem (thats what she said) that the clutch fork isnt getting pushed in far enough....
thanks
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Old 09-24-2007, 04:45 AM
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dude. a monkey would be better off replacing a clutch over myself. bump
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Old 09-24-2007, 06:56 AM
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more info

hey just another bit o info

I called the tech line for the company that made the clutch, they said that it sounded like I had air in the line, which is causing the large amount of freeplay..... Anybody??? What do you think??? My head hurts....
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Old 09-24-2007, 07:53 AM
AJF AJF is offline
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Bumpity Bump
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Old 09-25-2007, 03:12 AM
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Anybody??

I really think its a hydr. problem......
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Old 09-25-2007, 03:21 AM
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what year model is it , that will make a difference how to address it
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Old 09-25-2007, 09:10 AM
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early 99 - 4x4 f350 7.3 zf trans, 6 speed. I put a new valero clutch in it, the old setup and for that matter the new doesnt/didnt have a dual mass flywheel

Thanks
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Old 09-25-2007, 09:17 AM
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Quote:
Originally Posted by pcutrer View Post
early 99 - 4x4 f350 7.3 zf trans, 6 speed. I put a new valero clutch in it, the old setup and for that matter the new doesnt/didnt have a dual mass flywheel

Thanks
go to ford buy a complete hydraulic kit from ford, make sure the lever under the dash isnt worn to bad , , youll have to buy the rod that goes into the master cylinder also, that should take care of it
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Old 09-25-2007, 09:33 AM
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thanks - I got the pre-beld kit, I didnt get that pushrod though, the one with the eyelet. How does it disconnect from the old master?
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