Hello...a few week ago, my '95 F150 5-speed 4X started having clutch problems. The little bushing or grommet on the clutch master cylinder plunger that attaches to the stud in the clutch pedal lever popped off, making the clutch pedal go to the floor. Got another grommet, and that too broke. I have since changed the clutch pedal assebly bushings, and the problem is still there. Any ideas??? PLEASE help. I can't drive mt truck because of this stupid plastic crap!!! I heard there was a "firewall flex" problem with these. Could that be the cause?? Any one else have this problem? ANY hel would be appreciated. Thanks!!!!!!!

 

I've posted this problem several times without success. After replacing numerous bushings, I just got a locking ring, and forced it over the stud. Not as good as it should be, but it works.

 

Thanks for the reply guitar. I tried that too. i put a lock washer over the stud and pressed it on. I wound up busting the rod on the master cylinder, plastic piece of ****...Anyway, I think the problem is firewall flex. I know (or learned ) that ford makes a repair kit for this, and if that dosn't work, I'll just have a shop make one for me. I still have my old master cylinder so I can make a template. I will hold onto it in case anyone needs a template as I'm sure a lot of these old trucks will start to develop the same problem. If your fix fails, send me an email or msg. and I'll send you a template. I will have to wait to Tuesday to see if Ford still offers the kit. Thanks again.

 

Sounds Great. I plan to look at bracing the clutch system, and trying to isolate the problem. I may just fabricate a brace from angle iron, if need be. By the way, mine is a 91 F150, and I was lucky enough to have all metal clutch linkage, except that <censored> bushing. I think the bushing that's in there is worn down, because it's getting harder and harder to shift, and I'm getting a lot more grind. I also hear a nice squeak every time I change the clutch pedal position. Combine that with the 2 inches of free play before the pedal is even under pressure..... Grr.

 

well, my linkage is all metal, just the bushings along theat carrier rod are plastic. I actually discovered that flex is not my problem, I had the wife watch the clutch master cylinder as I worked the pedal. She said it didn't move, even though I could move the master cyl. easily w/ my hand. After doing it again, I noticed that the little neck close to the firewall was moving, not the firewall itself. Now, I'm guessing that the holes for that carrier rod are warn out-of-round. I'm going to pull it today and take a closerlook, in case I have to order one tomorrow. If I were you, I'd get on the problem. You're having the same symptoms I did. When the plastic grommet snapped, I made a metal retainer that fit in that groove on the little stud. I wound up snapping the piston rod that went to the cl. master cylinder--Had to buy a new one just to get that part. I second your " Grr..."