My clutch linkage is worn at all the pivot points,and all the rod ends, as well as the pedal,(shaft and rod bracket).
Are there replacements available,is there an interchange with pickups?
Someone else must have dealt with this problem,what is the solution?
This is a 1981 E150 4.9, 4 speed,with factory air,(if that matters).
Thank You!!!!

 

One way is to weld metal onto the rods and into the lever holes, build up the worn areas and then grind and drill back to size. If you or some one you know can weld, it's a good way to restore the parts. The bell crank, bolted to the frame below the pedal, has replaceable nylon bushings, or used to any way. Mine got so bad new bushings wouldn't help. I cut the crank lever off and welded it onto an auto trans "sun gear" (Chrysler TF-904) and used a stub of the 904 output shaft (the part the sun gear rides on) as the pivot, the stub shaft was welded to the orig. frame bracket and bolted in place on the frame. This worked so well, it even had a zerc fitting on the end to lube the two bronze bushings inside.
Again if you can do this your self it would be practical. The automatic trans parts, TF-904 sun gear and output shaft, (or other suitable small trans sun gear and shaft) can be had at your local trans shop for a case of beer or less, shops are scrapping this obsolete stuff these days.
Hope this helps, it worked for me.

 

I just remembered, you also need some thing to keep the sun gear on the shaft. I used a snap ring from the same trans, but relocated it directly in front of the sun gear, which is about a inch back from it's normal placement. The ring stayed in place because the shaft diameter is smaller in this area, than the splined end directly in front.
Sorry I cant add pics, the vehicle is long gone now.
Another way is to replace the manual with a C-6, which I also did, several years later.

 

When the linkage was getting a little sloppy in my '81 E150, 4.9L 300 w/3+1 OD Trans, I grafted on a Hurst Competition Plus shifter and linkage, I added an extension onto the stick so it came up to standard height.

 

Nice, very nice Turbogus, beats my 8-ball all to H-E double toothpicks!

 

welding them up as mentioned in post #2 is the only real way to restore them. if you're up for a little more of a project, you might consider swapping to a hydraulic system. in a pickup this swap isn't too hard - i upgraded my 83 with parts from my 86 that i was parting out at the time.

 

Thanks! and the odd thing was despite this being a German bier (one of my favorites, especially the dunkel) it was tapped (pardon the pun) SAE threads of the same size so it threaded right on. I asked several forums about the thread count and pitch was of beer tap handles but no one got back to me so when I purchased it on EBay I was considering having to convert or re tap the threads but it turned out unnessesary.