94 ZF5 clutch falling out? - Pirate4x4.Com : 4x4 and Off-Road Forum
 
Pirate4x4.Com : 4x4 and Off-Road Forum  

Go Back   Pirate4x4.Com : 4x4 and Off-Road Forum > Brand Specific Tech > Ford
Notices

Reply
 
Share LinkBack Thread Tools Display Modes
Old 06-23-2019, 12:20 PM   #1 (permalink)
Registered User
 
Join Date: Dec 2006
Member # 84339
Location: Flyover land
Posts: 16,112
94 ZF5 clutch falling out?

In my F350, I've got a 7.3L IDI, with the older ZF5 tranny. Had the trans replaced ~7 years ago, they put in a new clutch when it was R&R'd. When I swapped in the drivetrain, I put a new master cylinder/slave cylinder combo. Still the original clutch fork, AFAIK. Trans doesn't have too many miles on it - maybe 30-50K? over the last 7 years.

My problem is, when I'm driving down the road, occasionally, the slave cylinder falls off the bellhousing Clutch goes to the floor, and if you pump it another time, it spits out the slave cylinder rod, dust cover and retainer boot. It's pretty easy to put together - just compress it all back down, engage the tabs, and stick it back in. I'm wondering if the mounting tab clips for the slave cylinder just need to be crimped down cause they lost their spring.

Clutch seems to shift fine, no grinding between gears. The truck will sit for 1--2 months at a time, if not longer.

My googling come up with lots of problems with the actuating rod to master cylinder problems, but none like I'm having. One site suggested that the pressure plate had failed (or is in the process of failing), and should be replaced. No idea on what pressure plate is in there right now.

What say PBB?

94 ZF5, external slave cylinder falling off the bellhousing. Don't know what's causing it, looking for a direction.
__________________
Lugnut4x4.com
And i don't want to give Canadiens any more money, so my sig is broke.
Pt_Ranger_V8 is offline   Reply With Quote Quick reply to this message
Old 06-23-2019, 12:58 PM   #2 (permalink)
Zeus of the Sluice
 
dieselboy740's Avatar
 
Join Date: Sep 2010
Member # 168108
Location: Ramona
Posts: 3,854
Safetywire it on.
__________________
'97 f-250 7.3, project, 3 link front, 4 link rear, back halved, fox co/bypasses/bumps, etc....
'08 f350 cclb 4x v10
'93 Volvo 940 fake rally car #trophyvo
dieselboy740 is offline   Reply With Quote Quick reply to this message
Sponsored Links
Old 06-23-2019, 01:06 PM   #3 (permalink)
Registered User
 
YotaAtieToo's Avatar
 
Join Date: Dec 2003
Member # 25632
Location: Magalia, Jefferson State
Posts: 11,526
When I replaced my clutch, I found the fork to be worn completely through where it pivots on the little ball. Maybe the fork going further than its supposed to is causing the slave to over extend and have side load?
YotaAtieToo is offline   Reply With Quote Quick reply to this message
 
Old 06-23-2019, 02:09 PM   #4 (permalink)
Registered User
 
Join Date: Dec 2006
Member # 84339
Location: Flyover land
Posts: 16,112
Quote:
Originally Posted by dieselboy740 View Post
Safetywire it on.
Thoguht about that. A couple of self tappers into the bell would keep it in.



Quote:
Originally Posted by YotaAtieToo View Post
When I replaced my clutch, I found the fork to be worn completely through where it pivots on the little ball. Maybe the fork going further than its supposed to is causing the slave to over extend and have side load?
I thought about that. Do you know if the fork end of the actuator rod is supposed to have a rubber boot on it? Mine doesn't - in fact, the little 'eared' piece of plastic is about 1/4" down the rod
__________________
Lugnut4x4.com
And i don't want to give Canadiens any more money, so my sig is broke.
Pt_Ranger_V8 is offline   Reply With Quote Quick reply to this message
Old 06-23-2019, 09:16 PM   #5 (permalink)
Registered User
 
YotaAtieToo's Avatar
 
Join Date: Dec 2003
Member # 25632
Location: Magalia, Jefferson State
Posts: 11,526
Quote:
Originally Posted by Pt_Ranger_V8 View Post
Thoguht about that. A couple of self tappers into the bell would keep it in.





I thought about that. Do you know if the fork end of the actuator rod is supposed to have a rubber boot on it? Mine doesn't - in fact, the little 'eared' piece of plastic is about 1/4" down the rod
It's probably supposed to have some plastic thing that might last 10k miles. Kinda like the pice of plastic on the end of the master cylinder rod.
YotaAtieToo is offline   Reply With Quote Quick reply to this message
Old 06-25-2019, 05:17 AM   #6 (permalink)
Registered User
 
Join Date: Dec 2006
Member # 84339
Location: Flyover land
Posts: 16,112
Quote:
Originally Posted by YotaAtieToo View Post
It's probably supposed to have some plastic thing that might last 10k miles. Kinda like the pice of plastic on the end of the master cylinder rod.
Wait. There's a piece of plastic on the master cylinder rod?

I cobbled my rod together when I swapped to hydroboost. I *thought* 1/4" loinger was enough, turns out I needed 1/8" or less
__________________
Lugnut4x4.com
And i don't want to give Canadiens any more money, so my sig is broke.
Pt_Ranger_V8 is offline   Reply With Quote Quick reply to this message
Old 06-25-2019, 05:24 AM   #7 (permalink)
Registered User
 
YotaAtieToo's Avatar
 
Join Date: Dec 2003
Member # 25632
Location: Magalia, Jefferson State
Posts: 11,526
Quote:
Originally Posted by Pt_Ranger_V8 View Post
Wait. There's a piece of plastic on the master cylinder rod?

I cobbled my rod together when I swapped to hydroboost. I *thought* 1/4" loinger was enough, turns out I needed 1/8" or less
Where it pops onto the ball on the pedal assembly, talking about the clutch master though.
YotaAtieToo is offline   Reply With Quote Quick reply to this message
Old 06-25-2019, 09:04 AM   #8 (permalink)
Safety third!
 
Dr.Danger's Avatar
 
Join Date: Sep 2010
Member # 168243
Location: College Station, TX
Posts: 11,331
Quote:
Originally Posted by Pt_Ranger_V8 View Post
Thoguht about that. A couple of self tappers into the bell would keep it in.


The 4 speed aluminum bells use the same slave cylinder. Mine has a screw that holds the slave cylinder on. I'm surprised the ZF doesn't have a hole for that already.

I got to jump out and under the truck to put my slave cylinder back on once in the mouth of a busy intersection while cars were honking at me, because I forgot to put it back after snapping it on the mount. Yeah, it went right the fuck back on when I got home.
__________________
-Dave

Quote:
By the way, Irregardless does pass spell check and it is a word. The meaning is exactly the same, you just want to play games

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


For the best deal on 8 lug disc brakes click here-->
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Dr.Danger is offline   Reply With Quote Quick reply to this message
Old 06-27-2019, 07:49 AM   #9 (permalink)
Registered User
 
Join Date: Dec 2006
Member # 84339
Location: Flyover land
Posts: 16,112
Quote:
Originally Posted by YotaAtieToo View Post
Where it pops onto the ball on the pedal assembly, talking about the clutch master though.
Yeah. I caught the master.



looks like it's a couple of self tappers for the win this weekend
__________________
Lugnut4x4.com
And i don't want to give Canadiens any more money, so my sig is broke.
Pt_Ranger_V8 is offline   Reply With Quote Quick reply to this message
Old 06-27-2019, 11:07 AM   #10 (permalink)
Registered User
 
YotaAtieToo's Avatar
 
Join Date: Dec 2003
Member # 25632
Location: Magalia, Jefferson State
Posts: 11,526
Quote:
Originally Posted by Pt_Ranger_V8 View Post
Yeah. I caught the master.



looks like it's a couple of self tappers for the win this weekend
Self tappers don't work into solid material since the threads will start to try to grab while it's still drilling.
YotaAtieToo is offline   Reply With Quote Quick reply to this message
Old 06-27-2019, 11:40 AM   #11 (permalink)
Safety third!
 
Dr.Danger's Avatar
 
Join Date: Sep 2010
Member # 168243
Location: College Station, TX
Posts: 11,331
Quote:
Originally Posted by YotaAtieToo View Post
Self tappers don't work into solid material since the threads will start to try to grab while it's still drilling.
Yep. IIRC it's thick enough you wanna drill and tap but it won't take you long. The clip does most if not all of the work, the small bolt is just to keep it from sliding and working itself off with clutching. Mine only has the one bolt.
__________________
-Dave

Quote:
By the way, Irregardless does pass spell check and it is a word. The meaning is exactly the same, you just want to play games

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


For the best deal on 8 lug disc brakes click here-->
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Dr.Danger is offline   Reply With Quote Quick reply to this message
Old 06-30-2019, 09:39 PM   #12 (permalink)
Registered User
 
Join Date: Dec 2006
Member # 84339
Location: Flyover land
Posts: 16,112
Through drilled from the side, and I couldn't get the screws to bite - so I said fuck it, and drilled through the mounting bracket. It's gonna suck when I have to replace the slave, but by golly, it's working for now.
__________________
Lugnut4x4.com
And i don't want to give Canadiens any more money, so my sig is broke.
Pt_Ranger_V8 is offline   Reply With Quote Quick reply to this message
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Pirate4x4.Com : 4x4 and Off-Road Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.

** A VERIFICATION EMAIL IS SENT TO THIS ADDRESS TO COMPLETE REGISTRATION!! **

Email Address:
Insurance
Please select your insurance company (Optional)

Log-in


Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -7. The time now is 03:40 PM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
Search Engine Optimization by vBSEO 3.6.0 ©2011, Crawlability, Inc.
User Alert System provided by Advanced User Tagging (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.