I am converting a 75 ford f-250 4x4 from a 360 gas motor and 4 speed, to a 7.3 idi diesel and a zf 5 speed. The motor and tranney are out of an 88 f-superduty. I have the engine and tranney mounted, cab back on, and just put the pedals in today. I am using a manual clutch linkage. I hate hydraulic clutches after nothing but problems with them on my ford ranger. The problem I'm having is everything lines up and works smooth, but when I try to release the clutch, it takes a ton of pedal pressure to release the clutch. I has a stock dual mass flywheel, and stock clutch and pressure plate, looks to be pretty recently replaced. I can barely release it and when it does it takes alot of pressure to release, then it gets a little easier, like it has a breakover point. Does anyone know any companys that makes a custom clutch that would have a lighter pedal, but still have good pressure. The motor is stock and I am not going to try and make more power, I just want it to be able to pull my trailer, and have a decent clutch pedal

I'll have to try and get some pics on here, it's a regular cab 4x4, divorced np 205 transferase, I converted it to power steering, custom made all the mounts using the 88 motor mount plates, dana 60 front, 70 rear, dual rear wheels, 8 foot flareside bed, it's a complete frame off restoration/modification.

Thanks for any help

 

How did you set up the engine side mount for the Z bar? I went hydro on my conversion, for me it was easier than setting up a mechanical system. The IDI/ZF hydraulic clutch is quite different than the annular slave setup used on other trucks.

 

Stock, the hydraulic clutch takes quite a bit of pedal force. I changed over to a single mass flywheel in the summer, and I couldn't believe how much easier it is.

You may be able to adjust pivot points to change your leverage. I don't know a whole lot about mechanical clutches, but I do know how leverage works.

 

As stated above, go with a single mass flywheel conversion. You can really tell the difference when you change it over in a truck with the hydrolic setup, so I woul say it would be the same with the mechanical setup. Plus the DMF is a ticking time bomb in my opinion. I had one go bad and it cracked the case on the ZF.

 

I made a pivot bracket that bolts on the the transmission with the bellhousing bolts, works pretty good. I'll contact one of the companys that does the new flywheels, whats a good company to work with on those, I think south bend makes one, anyone else?

 

Luk makes one too, thats what I ended up putting on my truck when my (fairly new) DMF self destructed. Neither will be a cheap fix, but will help your situation. Also be sure you lubricated the quill where the throw-out bearing rides. When I got my truck it was hell stepping on the clutch, when I switched transmissions to go 4x4, I noticed the throw-out was hanging up, lubrication made a difference, but the big WOW! was going to an SMF