One thing with the clutch disc that could cause your symptoms. One of those little coil springs in the clutch disc may have come out of place and is binding in there between the flywheel or pressure plate and won't let the transmission input shaft stop when you push the clutch pedal down. I have experienced this and also read about it on these forums.

 

Yeah, I'm seeing that now. I don't have any experience with replacing clutches, so when I'm having trouble shifting a manual transmission, my mind thinks "bad clutch" and we go from there.

From what I understand, there is no syncro for the reverse gear in this transmission, so not fully disengaging seems to be the most likely explanation.

The PO told me that he always launched in second gear, so it wouldn't surprise me if the syncro was on its way out. Unfortunately, a transmission rebuild is simply out of the question for me right now, so that will have to be addressed at a later date.

 

Well, once I pulled the lower dash cover it took all of about five seconds to figure out that that bushing at the MC pushrod is fried.

The next question is, how much of a PITA is it going to be to replace?

 

a royal pain in the *** if you are a crippled old fart like i am.
i remember one guy about 8 years ago made a bronze bushing to replace the wasted nylon bushing because the hole was all wallowed out

 

Where can I find the actual process to replace it? I found the instructions for replacing the pedal box bushings, but that's not what I'm after. I'm young and able-bodied, my problem lies in the fact that I'm attending work training and away from home. However, I have a class full of heavy equipment students who're ready and willing to do the work on it for me.

 

i found this: https://www.ford-trucks.com/forums/7...ml#post5794495

unfortunately, i never had to replace the bushing so i can't help you on that part.

 

It's really simple on these trucks.
Pop the master cylinder pushrod off with a big screwdriver or small pry bar.
Put the new four fingered bushing in the'eye' of the pushrod, and click it into place.

I used a pistol casing with a snap ring in the extractor groove for a while, and then made an oilite bronze bushing with a washer retained by a hairpin clip.

You can get the plastic clip from the autoparts store.
it's found in a Dorman assortment of windshield linkage retainers.

 

Oh wow, that's even easier than I thought. I figured I'd at least have to unbolt the MC and pull it off the firewall a ways in order to remove it from the pedal arm.

Already ordered a Ford OEM bushing. Out here in the boonies nothing's cheap, and NAPA would have to ship one in from the city. Just as easy to order online.

 

$3.99 for the whole assortment seemed a lot better than paying stealership markup and having to wait.

I can understand, if you are way out in the sticks.

 

Well I ordered it on Amazon, so hopefully there wasn't too much of a markup. $11 part, $12 shipping

 

You can see the four fingered clips here.
It's an add-on item, so you only get free two day shipping if you combine it with something else

http://www.amazon.com/Dorman-49447-W.../dp/B000IWFPIW

 

still cheaper and easier than a clutch job!!!

 

That's what I'm saying!

Although, this clutch is past the 160k mark, so chances are it'll need replacement sooner or later. And I really should pull the transmission at some point and have it serviced, bearings and syncros checked...