i happen to be in the middle of a cummins swap now with a ZF5spd tranny but i dont have a clutch pedal in my truck cause it was an auto. I was looking at a universal firewall mount pedal with MC and resevoir. BUT this is where im unsure the stroke length of it is 1.1 inches and if anyone has a clue if this will be enough to engage and disengage the clutch? Thanks for the help
Summit Racing 14-0013 - Summit Racing® Master Cylinder and Pedal Pro Packs - Overview - SummitRacing.com

 

I happen to be in the middle of the same swap. Don't mess with all that universal stuff, just go to the wrecking yard and get a stock pedal and use the master that would have come in a truck with the ZF5. That way you know the slave will work properly since the aftermarket master might not move enough fluid for the big slave on the ZF, and you will be able to hook them together since the slave and MC have special ends that require a specific hose. I can take pictures of all that stuff and post it later today. My truck was an auto also but I have another truck sitting around that I stole the clutch pedal out of. In order to install a factory clutch pedal all you have to do is remove the shaft that the brake pedal hangs and swings on and replace it with the clutck pedal assembly.

As far as hooking up the MC goes it will mount inboard of the brake master just like the late model trucks have it. You can use the same lever that the that the mecanical linkage used to hook to but it will need to be rotated so that it swings fore and aft instead of up and down. I accomplished this by cutting the weld where the shaft attaches to the pedal and rotating it to the position I wanted. When I mock it up and get everything it the final position I will weld it back together.

Hese's where I cut the weld

<a href="http://s742.photobucket.com/albums/xx65/Fordworth/?action=view&amp;current=IMG_20110525_161120.jpg" target="_blank"><img src="http://i742.photobucket.com/albums/xx65/Fordworth/IMG_20110525_161120.jpg" border="0" alt="Photobucket"></a>

Here's how I positioned the lever. I haven't actually installed the MC yet but this seems to be about the right spot. It also seems to have the right amount of stroke for the stock MC.
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I'll get more pics later that will help to explain the process better, but it's really pretty easy.

 

I read somewhere here that people were having trouble with the firewall cracking where the Master Cylinder was installed. Anyone know about this? I'm prepping for a ZF conversion and haven't decided on manual or hydraulic.

 

I'm going to add a plate to the firewall for reinforcement. Others have had success with that.

 

Thats exactly how I plan on doing mine. I'm just kinda stalled out on mine right now. I actually have a complete extra pedal assy, and am going to use it and a peice of sheet metal to mock everything up BEFORE I start cutting and drilling the firewall on my truck. I'm also going to go to a hydroboost, so I'm hoping I can build a combined mount/stiffener for the both of them.

 

Also, if the stock lever doesnt provide the correct stroke, you could adjust that by building a longer or shorter lever. I haven't gotten that far yet though. What are you dropping in your truck? A 4bt or 6bt?

 

If you're asking me , I'm using a 6. It's under the plastic in the backround.

Here's why I think it's best to stick with the factory hydraulic components. They're already designed to work with the trans and clutch and replacement parts are easy to come by at the local parts house. Here's what the setup from a 1990 F350 witha 7.2/ZF5 combo looks like.


<a href="http://s742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/?action=view&amp;current=IMG_20110526_134805.jpg" target="_blank"><img src="http://i742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/IMG_20110526_134805.jpg" border="0" alt="Photobucket"></a>

Here are the hose ends that slip into the master and slave respectively. Good lock trying to match this stuff with aftermarket parts.
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<a href="http://s742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/?action=view&amp;current=IMG_20110526_134825.jpg" target="_blank"><img src="http://i742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/IMG_20110526_134825.jpg" border="0" alt="Photobucket"></a>

The master is going to end up in this area, though closer to the rubber grommet than my black circle. Unfortunately it will be a couple inches away from the lever on the pedal in order to clear the vacuum booster so I will have to make a spacer where the rod attaches to the lever. I haven't gotten to that yet. Another option is to convert to hydroboost at the same time to save space.
<a href="http://s742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/?action=view&amp;current=IMG_20110526_135018.jpg" target="_blank"><img src="http://i742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/IMG_20110526_135018.jpg" border="0" alt="Photobucket"></a>

As far as the pedal install goes, this is what the assembly looks like disasembled.
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The lever and shaft aren't splined like the later models which is why you have to cut the weld and rotate the shaft like I showed earlier. This is a good time to replace the shaft bushings you see in the right of the pics.
<a href="http://s742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/?action=view&amp;current=IMG_20110526_130352.jpg" target="_blank"><img src="http://i742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/IMG_20110526_130352.jpg" border="0" alt="Photobucket"></a>

Here's what it will look like under the dash after installation. The brake pedal is just hanging loose right now since the clutch pedal has been in and out several times and will be several more I'm sure. My satalite radio tuner is going to have to find a new home. Any ideas?
<a href="http://s742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/?action=view&amp;current=IMG_20110526_140758.jpg" target="_blank"><img src="http://i742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/IMG_20110526_140758.jpg" border="0" alt="Photobucket"></a>

<a href="http://s742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/?action=view&amp;current=IMG_20110526_140726.jpg" target="_blank"><img src="http://i742.photobucket.com/albums/xx65/Fordworth/Hydro%20Clutch%20Conversion/IMG_20110526_140726.jpg" border="0" alt="Photobucket"></a>


Hey 78 PEB, do you know of any good threads on the hydro boost conversion?

 

No, I have seen some say to use one out of the later model Super Duties and some say to use one from a Astro van. I just pulled one out of a 78 or 79 Chevy Dually that looks to me like it has potential. It appears to have the same bolt pattern on it as the vacuum booster on my 78 F150. Like I said before, I've kinda got stalled out on my 4BT / ZF5 swap right now but, hope to get back to it soon. My ZF has the internal slave on it so thats about the only difference between what youre doing and what I'm doing. When I get to figuring out the slave / hydro boost, I'll be posting it in my build thread. I'm thinking I can do a lot of the figuring out and planning by using the extra pedal assy. I have and some sheet metal to simulate the firewall and do most of the planning and fabbing on the work bench instead of standing on my head under the dash LOL. Keep us posted on your slave install...............And BTW..........Where did you get the cross shaft bushings? Are they still available from Ford?

 

I forgot that they used the internal doughnut style slave on the ZF5, I was thinking it was just on the 6's and the little small block mazda trannys. The master idea is the same though.

I found the hydroboost thread you posted in recently. I think I'm going to do as part of my project. The local self serve wrecker is having their 50% sale this weekend so that puts them in line with the prices the rest of you guys pay in real America (as opposed to here in comunistfornia).

The bushings came from Dennis Carpenter. I think they were $1 each.

Hijack complete.