Ok, update of my experiences

Yesterday I spent most of the day doing the repair and it all paid off. Probably could have done it quicker but it was cold, windy, and I don't like laying in the stones.


First here is the part that I got:


The OEM one was a plastic body with no Ford stamping anywhere. It was stamped USA so thats usually a good sign.

In the package were the TSB's about clutch issues which was really nice to have. Had all the part numbers for the firewall bracket and everything else.

I attempted to bench bleed the new slave:



All I did was set it in a pie pan to keep from making too much of a mess and filled it up at the port until I didn't see any air bubbles come up. I did work the plunger a little bit and kept the port side higher so hopefully any air would work out.


Here is what the original looked like. Not sure why but the picture is backwards:



As you can kinda see its a bit damp at the bellows. After i removed it I found that the bellows were full of brake fluid. It appears one of the seals let go.


At this point I stopped taking pictures, kinda hard to do 3 things with one hand.


Install and removal wasnt bad, just kinda pry on the clip alittle bit to get it off of the bracket and it pops out.

After that use a 3/32 punch to drive out the roll pin. Don't loose it. The new slave does come with a new o-ring and roll pin, but I lost the new roll pin. Luckily I still had the old one.

I removed the old and installed the new. I removed the little plastic retainer and installed the new slave back on the transmission.

At this point I pumped and pumped and pumped and pumped and pumped (and pumped) the clutch pedal. I had nothing.

After doing that for way too long I removed the slave from the trans again and pumped it underneath the truck. This allowed me to work the air out of the system. Did that a bunch of times until my arms were tired, took a break, and reinstalled the slave. After doing this I pump the pedal and finally had something. Had to do that a handfull of times and success!

So hopefully that helps someone do it a little quicker than me lol

I recomend having a friend to watch the master resevoir, plenty of rags, and probably some safety glasses to avoid getting brake fluid in the eyes whenever you push it too far and overflow the resevoir (d'oh) would help.

 

glad you got it fixed, my problem ended up just being the oring that goes between the slave and line up.

 

You and me both haha

Glad you got yours squared away too. I was kinda surprised how simple it turned out to be. Gotta love these old trucks

 

Yup sure do, thats why ive got 3 workin on a 4th!! lol

 

You don't want to remove the plastic retainer!

It acts as a short of shim at the end of the rod to keep the metal on metal contact from wearing either the rod or the clutch fork down.
I would put it back on if you can. It also helps to hold the rod in while you slide the slave into place, but is designed to pop off or break the side parts when you hit the pedal.

 

Oh really? Did not know that, I figured it was just an assembly piece so that the rod wasnt flopping around.

I can put it back in as I saved it, but can anyone else confirm what tecgod's saying?

There wasn't one in there when I removed the old one, not that it wasnt replaced before. It was an oem piece though

 

I left mine in when I replaced my slave cylinder. It helped close the 1/16" gap between the push rod and clutch arm. And now my clutch friction point is just a little higher up from the cab floor, which I like.

 

Ok gotcha, thanks fellas

The clutch feel is great now, feels like it should. Maybe I dont need that in there but I will probably install it just for peace of mind.

 

That plastic retainer is for assembly only, it usually falls out once the clutch is depressed and even when it doesn't it walks over to one side and doesn't do anything. Do not worry about it not being there, it's fine without it.

 

I disagree, it can't "fall out" its sandwiched between the push rod and the clutch fork. There shouldn't be any free space there.
You are right its meant for assembly, and the two straps will either break or stretch upon first use. But the ball part stays on the end of the push rod.