Go Back   Ford Truck Enthusiasts Forums > Older, Classic & Antique Trucks > 1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks
Sign in using an external account
Register Forgot Password?


1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks Discuss the Early Eighties Bullnose Ford Truck

Welcome to Ford-Trucks Forums!
Welcome to Ford-Trucks.com.

You are currently viewing our forums as a guest, which gives you limited access to view most discussions and access our other features. By joining our community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join the Ford-Trucks Forums community today!





 
Reply
 
LinkBack Thread Tools Search this Thread
  #1 (permalink)  
Old 03-19-2011, 03:03 PM
axman_F250's Avatar
axman_F250 axman_F250 is offline
Junior User
 
Join Date: Sep 2009
Posts: 93
axman_F250 is gaining momentum as a positive member of FTE.
hydraulic clutch, firewall flex repair

My beast.. 84 F250, 460, T19.

Among many other repairs, I'm doing the clutch, pressure plate, throwout & pilot bearings, and surface the flywheel. Also will replace clutch master cyl, slave cyl, and hose. Reading about clutch issues here, I learned about firewall flex. My firewall is cracked 3 places around the clutch master cyl.

Click the image to open in full size.

Also, the clutch master cyl push rod is seriously worn, as is the stud on the pedal bellcrank arm - the stud is about 1/2 gone..

Click the image to open in full size.


So, I lurked here a while and found a good post.

http://www.ford-trucks.com/forums/36...forcement.html

I think I will fab the firewall reinforcing plate rather than try to buy it. That doesn't look too hard. I can also weld the cracks in the firewall once the master cyl is out..

So - does anyone have a picture or template of the reinforcing plate? Without having that as guideline, I would just make a plate the same shape but slightly larger than the master cyl. Is this reasonable? Or should the reinforcing plate also go behind the brake booster+master cyl?

I read here that Ford offered two repair kits for this issue back in the day. One for simple damage repair, and one for severe damage repair. My guess is the severe damage kit was just a bigger plate, covering more area. Did it extended behind the brake master+booster? Did it follow the curve of the trans hump?

From what you can see in the pics, is the damage I have considered severe? Is welding up the cracks and going with small reinforcing plate enough? After doing this much work, it seems silly to "half@$$" it.

Feedback is most appreciated. Thanks
Reply With Quote
  #2 (permalink)  
Old 03-19-2011, 08:39 PM
Franklin2's Avatar
Franklin2 Franklin2 is offline
Moderator
 
Join Date: Jan 2001
Location: Staunton VA
Posts: 32,432
Franklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant future
I would see if the Ford dealer has any left in stock.

Here's a link with some info.
Firewall Re-inforcement plate - Oilburners.net
__________________
Dave F

1989 F250 XLT Diesel
Reply With Quote
  #3 (permalink)  
Old 03-19-2011, 09:51 PM
axman_F250's Avatar
axman_F250 axman_F250 is offline
Junior User
 
Join Date: Sep 2009
Posts: 93
axman_F250 is gaining momentum as a positive member of FTE.
Thanks very much. I'll check with local dealer Monday, but his part looks like the way to go. Much obliged.
Reply With Quote
  #4 (permalink)  
Old 03-19-2011, 10:06 PM
IDIDieselJohn's Avatar
IDIDieselJohn IDIDieselJohn is offline
Post Fiend
 
Join Date: Feb 2009
Location: Ottawa, Ontario
Posts: 7,791
IDIDieselJohn has a very good reputation on FTE.IDIDieselJohn has a very good reputation on FTE.IDIDieselJohn has a very good reputation on FTE.IDIDieselJohn has a very good reputation on FTE.
Apparently that part is discontinued, theres a guy over on OilBurners.net that makes them better than the Ford ones.
__________________

1990 Ford F250 4x4, ZF5, L/S 4.10, N/A 7.3L Diesel, 568,808km/377,497 miles, still on the original clutch!
1989 Ford F150 300-6, C6, 2.73, 135,000km/84,000 miles.
1987 Ford E350 26ft. Motorhome, N/A 6.9L Diesel, C6, 3.54, 277,000km/173,000 miles.
1985 Ford E350 Ext Van, 6.9L Diesel, C6, 4.11, 670,000km/419k miles
Reply With Quote
  #5 (permalink)  
Old 03-19-2011, 10:11 PM
axman_F250's Avatar
axman_F250 axman_F250 is offline
Junior User
 
Join Date: Sep 2009
Posts: 93
axman_F250 is gaining momentum as a positive member of FTE.
Quote:
Originally Posted by IDIDieselJohn View Post
Apparently that part is discontinued, theres a guy over on OilBurners.net that makes them better than the Ford ones.
Thanks for the tip. The link Franklin2 shared was who I think you're referring to.
Reply With Quote
  #6 (permalink)  
Old 03-19-2011, 10:16 PM
IDIDieselJohn's Avatar
IDIDieselJohn IDIDieselJohn is offline
Post Fiend
 
Join Date: Feb 2009
Location: Ottawa, Ontario
Posts: 7,791
IDIDieselJohn has a very good reputation on FTE.IDIDieselJohn has a very good reputation on FTE.IDIDieselJohn has a very good reputation on FTE.IDIDieselJohn has a very good reputation on FTE.
Yup, that's him. I have to order one my self for my new cab.
__________________

1990 Ford F250 4x4, ZF5, L/S 4.10, N/A 7.3L Diesel, 568,808km/377,497 miles, still on the original clutch!
1989 Ford F150 300-6, C6, 2.73, 135,000km/84,000 miles.
1987 Ford E350 26ft. Motorhome, N/A 6.9L Diesel, C6, 3.54, 277,000km/173,000 miles.
1985 Ford E350 Ext Van, 6.9L Diesel, C6, 4.11, 670,000km/419k miles
Reply With Quote
  #7 (permalink)  
Old 03-20-2011, 06:32 PM
ArdWrknTrk's Avatar
ArdWrknTrk ArdWrknTrk is offline
<---Dog is my co-pilot
 
Join Date: Jan 2008
Location: EXTREME southwest CT
Posts: 17,859
ArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputation
You might check out a thread titled "Frankenstein drivetrain issues" There are some good pic's in there.
__________________
Jim (AKA Princess Glitzhooter)
'87 F-250
460, 4V 0-80457s, Edelbrock Intake, Saginaw PS Pump, BW 1356 4x4, 4.10 10.25", 130A 3G Alt., PMGR starter, ZF-5, - Lil' Red
http://i246.photobucket.com/albums/gg117/donjamer/FTE%20Pics/blumax500-1-1.jpgFTE Fraternity of Blue Max
Reply With Quote
  #8 (permalink)  
Old 04-13-2011, 11:24 AM
axman_F250's Avatar
axman_F250 axman_F250 is offline
Junior User
 
Join Date: Sep 2009
Posts: 93
axman_F250 is gaining momentum as a positive member of FTE.
I've been reading and wrenching on how to fix this.

I found my way to Terrapin Mfg - http://www.terrapinmfg.com

I contacted Jason, the owner, and obtained one of his smaller reinforcing plates. While waiting for delivery, I wire welded the cracks from the engine compartment side. I suck at welding, but eventually got enough penetration without burning holes that couldn't be filled. It does not re-crack when the firewall is flexed. Click the image to open in full size.

I got the Technical Service Bulletin regarding "Clutch" from the Terrapin website, and read it thoroughly.

Once the part arrived, I began with test fitting. The 90 degree bend in the flange where the part attaches to the tranny hump would need to bend open a little. The TSB states that the service bracket might have to be bent to fit, which was the case for me. I bent the flange open a little at a time, until it fit flush. On the bench, you can see how much bend it took for a flush fit. Instead of a 90 degrees,about 75 made it fit nice for me.
Click the image to open in full size.

I did not have to hammer the firewall at all to get a good fit. Just a slight change in the bend. Bolted the part in, & drilled the extra holes using the part as template. I only screwed up 2 out of 4 holes.. (facepalm) But the reinforcing bracket from Terrapin fits nice. Click the image to open in full size.

Click the image to open in full size.

My original plan was to try and make this reinforcement bracket out of scrap, but I'm glad I didn't go that route. I'm happy with the part and the good service from Terrapin. It saved me time, and it's of far better quality and finish than I could quickly produce. It's worth the money. I'd recommend this solution for anyone else that has the smaller firewall cracks.

Thanks to franklin2, IDIDieselJohn, ArdWrknTrk for the suggestions and references.

Thanks to Jason @ Terrapin for making a needed part!
Reply With Quote
  #9 (permalink)  
Old 04-13-2011, 08:41 PM
fellro86's Avatar
fellro86 fellro86 is offline
Iowa Benevolent Dictator
 
Join Date: Feb 2004
Location: Marengo, Iowa
Posts: 11,526
fellro86 has much to be proud offellro86 has much to be proud offellro86 has much to be proud offellro86 has much to be proud offellro86 has much to be proud offellro86 has much to be proud offellro86 has much to be proud offellro86 has much to be proud of
I got lucky and the local Ford dealership had one in stock, $15 out the door. I didn't feel like fighting to get the hole drilled and bolted in the trans hump, so I welded that, but did the holes for all the other bolt holes around the master cylinder. Worked nice, but be aware the studs on the master cylinder may be too short, mine were pretty close. There was mention of extenders in the kit, but they were extra.
__________________
the workhorse:86 F250 4x4 6.9 Diesel 4-spd, 4.10 axles
the other workhorse 92 F350 2wd crew cab,3.55 rear axle, 92 6bt Cummins, NV4500
the project: 78 F150 4x4 shortbed 351 auto
Iowa Chapter leader, ASE certified parts specialist
Come on down and join us in the Iowa chapter, or your own local chapter!! Thanks, Roger
Reply With Quote
  #10 (permalink)  
Old 04-14-2011, 01:34 AM
ArdWrknTrk's Avatar
ArdWrknTrk ArdWrknTrk is offline
<---Dog is my co-pilot
 
Join Date: Jan 2008
Location: EXTREME southwest CT
Posts: 17,859
ArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputationArdWrknTrk has a superb reputation
My Ford kit came with longer studs.
In fact, I just saw the shorter ones when sorting through my 'bin o' bits' the other day.
Excellent follow up axman. Great photos.
Rep sent!
__________________
Jim (AKA Princess Glitzhooter)
'87 F-250
460, 4V 0-80457s, Edelbrock Intake, Saginaw PS Pump, BW 1356 4x4, 4.10 10.25", 130A 3G Alt., PMGR starter, ZF-5, - Lil' Red
http://i246.photobucket.com/albums/gg117/donjamer/FTE%20Pics/blumax500-1-1.jpgFTE Fraternity of Blue Max
Reply With Quote
  #11 (permalink)  
Old 04-14-2011, 07:30 PM
ebodell's Avatar
ebodell ebodell is offline
Senior User
 
Join Date: Dec 2010
Location: Southwest Iowa
Posts: 129
ebodell is starting off with a positive reputation.
Great post Axman. Unfortunately I am facing the same repair on mine. I do not have any cracking yet but I am getting some flex so I am afraid it is just a matter of time. Better to fix it in the summer than try and do it in the winter.
__________________
Erik
1985 F150 XLT/Lariat
300-6, 4sp OD trans, DSII conversion
Reply With Quote
  #12 (permalink)  
Old 04-14-2011, 11:42 PM
custom1106's Avatar
custom1106 custom1106 is offline
Senior User
 
Join Date: Jun 2006
Location: Phoenix, AZ
Posts: 265
custom1106 is starting off with a positive reputation.
Yep the smaller of the two kits are still avail, at least at my local ford dealer...Jim Babbit Ford in Flagstaff, AZ. As of 3 weeks ago, the kit was around $16 and solved my rough shifting issues. I too was thinking about making my own bracket, but the $16 was money well spent.
__________________
My Fleet...

1994 F150 XL 4x4 / 300 / C6 swap / 3.08's
1995 F150 XL 4x2 / 351 / E4OD / 3.55's
2005 Explorer XLS /4.0 V6/ 5R55E / 3.55's
Reply With Quote
  #13 (permalink)  
Old 04-15-2011, 09:55 PM
joshofalltrades joshofalltrades is offline
Postmaster
 
Join Date: Feb 2011
Posts: 3,512
joshofalltrades has a good reputation on FTE.joshofalltrades has a good reputation on FTE.
i fabbed my own reinforcement plate for a couple trucks. i took 1/4" plate steel, one piece from behind the brake booster extending all the way over to that metal lip just past teh clutch MC. you'll want to bore out the holes in the original sheet metal to a size that your nut and socket can slide through, otherwise your studs are too short. with the plate supported ONLY behind the brake booster, it had enough strength to not flex when pushing the clutch, but for good measure i think i added a couple bolts into the sheet metal. this was before i heard about the FoMoCo kit, but i would venture to say that my design is equal or better in terms of performance
Reply With Quote
  #14 (permalink)  
Old 04-15-2011, 10:11 PM
ebodell's Avatar
ebodell ebodell is offline
Senior User
 
Join Date: Dec 2010
Location: Southwest Iowa
Posts: 129
ebodell is starting off with a positive reputation.
I am going to check the local Ford dealer and see if they possibly still have a kit on the shelf. $16 sounds good to me and I try and buy most of my parts from the JY. A lot of guys on the site can probably fab one up for less than $16 but I am most likely not one of them. I am sure I could make something work but the frustration alone is worth the $16 to me. I have to replace the slave cylinder soon anyway so might as well fix it right and take care of the flex at the same time.
__________________
Erik
1985 F150 XLT/Lariat
300-6, 4sp OD trans, DSII conversion
Reply With Quote
  #15 (permalink)  
Old 04-15-2011, 10:12 PM
Franklin2's Avatar
Franklin2 Franklin2 is offline
Moderator
 
Join Date: Jan 2001
Location: Staunton VA
Posts: 32,432
Franklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant futureFranklin2 has a brilliant future
Quote:
Originally Posted by joshofalltrades View Post
i fabbed my own reinforcement plate for a couple trucks. i took 1/4" plate steel, one piece from behind the brake booster extending all the way over to that metal lip just past teh clutch MC. you'll want to bore out the holes in the original sheet metal to a size that your nut and socket can slide through, otherwise your studs are too short. with the plate supported ONLY behind the brake booster, it had enough strength to not flex when pushing the clutch, but for good measure i think i added a couple bolts into the sheet metal. this was before i heard about the FoMoCo kit, but i would venture to say that my design is equal or better in terms of performance
If your fix puts the plate under the hood, this will space the clutch master out that much, and one of the adjustable pushrods for the master cylinder will be a must, or your clutch pedal will be too low.
__________________
Dave F

1989 F250 XLT Diesel
Reply With Quote
Old 04-15-2011, 10:12 PM
Reply

Go Back   Ford Truck Enthusiasts Forums > Older, Classic & Antique Trucks > 1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks

Tags
150, 1986, 1987, 96, clutch, f150, f250, fire, firewall, flex, ford, recall, repair, repairing, troubleshoot, truck, wall

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not 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 On
Trackbacks are On
Pingbacks are On
Refbacks are On
Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
firewall finally reinforced, thx freebird 86f350 Pre-Power Stroke Diesel (7.3L IDI & 6.9L) 6 07-23-2014 10:07 AM
Firewall Reinforcement Plate airdale94 Pre-Power Stroke Diesel (7.3L IDI & 6.9L) 0 05-23-2014 08:33 PM
ZF Swap Hit a Snag! MPoulson Pre-Power Stroke Diesel (7.3L IDI & 6.9L) 16 09-21-2013 03:42 PM
Firewall cracks at the clutch master cylinder 86fordtruck 1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks 23 12-09-2012 08:01 PM
Fire Wall clutch plate 101 riotwarrior 1978 - 1996 Big Bronco 13 12-04-2012 08:01 PM



All times are GMT -5. The time now is 11:02 AM.


Powered by vBulletin® Version 3.7.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Advertising - Terms of Use - Privacy Statement - Jobs
This forum is owned and operated by Internet Brands, Inc., a Delaware corporation. It is not authorized or endorsed by the Ford Motor Company and is not affiliated with the Ford Motor Company or its related companies in any way. FordŽ is a registered trademark of the Ford Motor Company.

vbulletin Admin Backup