Need Help! Clutch Lever alignment Issue...
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Junior Member
Joined: Aug 2003
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Need Help! Clutch Lever alignment Issue...
... The Clutch lever on my 84 F250 is out of alignment. A previous owner had done some SERIOUS jurry rigging and had the linkage ALL fugged up. :-X09
So, I went to the local Ford Dealer to buy part # E4TZ-7A554-A.
The oldtimer said that the part was no longer available and was replaced by E7TZ-7A554-AA.
I installed it and the Clutch Master cylinder rod does NOT line up to where the lever's pin is located. It seems as though the lever's pin needs to be on the opposite side to be in proper alignment.
Turning the lever around puts the pin WAY out of alignment.
More research revealed this document with the lever's pin facing in the opposite side (Correct for my application ??) Here's the pic...
So my question is, did Ford actually swap the Lever's pin location on the updated part or what ??
How do I get this darn lever's pin to line up properly ??
So, I went to the local Ford Dealer to buy part # E4TZ-7A554-A.
The oldtimer said that the part was no longer available and was replaced by E7TZ-7A554-AA.
I installed it and the Clutch Master cylinder rod does NOT line up to where the lever's pin is located. It seems as though the lever's pin needs to be on the opposite side to be in proper alignment.
Turning the lever around puts the pin WAY out of alignment.
More research revealed this document with the lever's pin facing in the opposite side (Correct for my application ??) Here's the pic...
So my question is, did Ford actually swap the Lever's pin location on the updated part or what ??
How do I get this darn lever's pin to line up properly ??
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Joined: Jan 2003
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From: New Engand
Well, if the parts guy is showing the same pedal asembly as the one in your truck, the alignment problem would have to be the clutch master cylinder. Does it looked like it was moved at all? Any empty bolt holes in the area? Is there a piece of sheet metal behind the cl. master cylinder? The cl. master cylinder should fit directly opposite of the little stud that holds the master cylinder rod. There was a firewall flex issue with those trucks. Make sure the master cylinder lines up when attached to the bracket.
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Originally Posted by Katmandu
Well after many hours of blood, sweat and tears, I've solved the alignment issue.
Turns out that the 87-96 Lever is entirely different than the 80-86 lever.
Now what I don't understand is this.....
Ford changed the Clutch Lever (aka Bellcrank) starting in the 1987 model year. The biggest change was the OFFSET. There is at least a 1" difference in Offset between the old style lever.
The new style lever (87+) will NOT line up (behind the clutch master cylinder) properly in a 80-86 truck.
Q: Did Ford make a change in the location of the clutch master cylinder in the 87+ trucks to make up for the bellcrank offset difference from the previous years ???
Here's pics of the (2) levers below......
The 87+ Lever is the heavily angled part.
Turns out that the 87-96 Lever is entirely different than the 80-86 lever.
Now what I don't understand is this.....
Ford changed the Clutch Lever (aka Bellcrank) starting in the 1987 model year. The biggest change was the OFFSET. There is at least a 1" difference in Offset between the old style lever.
The new style lever (87+) will NOT line up (behind the clutch master cylinder) properly in a 80-86 truck.
Q: Did Ford make a change in the location of the clutch master cylinder in the 87+ trucks to make up for the bellcrank offset difference from the previous years ???
Here's pics of the (2) levers below......
The 87+ Lever is the heavily angled part.
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Joined: Jan 2003
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From: New Engand
I'm going to say they moved the cilinder, as the assembly needs to also hold the brake booster, and the top bolts need to be in line. You need to get yor clutch master cylinder installed in line with the pedal assembly you're going to use. I don't know why someone played with linkage to compensate for the ~1" rather than just moving the cylinder. Anyway, you have to nake sure the thing is lined up exactly. If you can't do it, find a mechanic who will--It needs to be pretty exact as to location. Also, you should modify your bushing setup. see my post titled 'pedal bushing issue' in this forum. . Also, Make sure your firewall is strong. There is a known issue re: firewall flex. Do a search to learn more.
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Joined: Jan 2003
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From: New Engand
Just remembered...the lever pin on my new assembly was not pressed on. I guess it's so you can put it in the direction you want. If you get a new one, put in the bracket and loosely fit everything linkage-wise to see if it lines up.