Well I set out looking for a plow setup for my '93 F250 and ended up finding a good Curtis plow that came with a truck! LOL. It's a 1990 F350, ZF5, and for some reason it has a 6.9 in it. It also has Banks turbo on it. This old truck is rough and is gonna need some work. I don't really care how it looks cause I'm just gonna plow and pull mowers around with it so I'm not gonna worry about the body. It needs glow plugs or a GP relay or both, definitely needs return lines, they are leaking bad. Those issues are no big deal and a cheap fix. The main issue is the clutch. The kid I got if from said he was coming home from plowing the other day and as he went to stop at a red light, the clutch master or slave "blew a seal". If you push the clutch pedal all the way against the floor, it will barely disengage enough to be able to stop without killing the engine. Once you get it going and driving down the road, it shifts with no grinding or anything. I'm not actually sure if the problem is with the master/slave or if it's the clutch itself. What do you guys think? On a good note, the old 6.9 runs and sounds great!

 

Looks good!! Is the fluid level full in the master/slave for the clutch? Thats all I can think of. Someone will come along with better advice than me. I've never really dealt with the hydraulic system on the ZF5 much.

 

The fluid level would be a good place to start! LOL. I didn't even look at it, I just drove it enough to pull it up on the trailer and back it off when I got it home. I'll check that first.

 

Definitely check the fluid level, and the firewall to see if its flexing.

 

Make sure you pull the rubber plug after you pull the cap, or else you'll just pour fluid everywhere like I did, whoops

My slave cylinder went out and the truck wouldn't go into gear when running, I noticed it was starting to go because the pedal started going to the floor and not do anything clutch related

 

Yep that's what this one is doing. The master is full of fluid. I'm betting it's the slave. I'm gonna tear into it in the next few days. These ole trucks are working me to death! Lol. I just got done putting an oil cooler in my 6.0, whoever thought it was a good idea to design that oil cooler to be under the intake manifold must have a really sick and twisted mind! My '93 F250 is still running on the original IP so I've got that to look forward to in the near future as well.

 

open the hood, and have someone step on the clutch to the floor while you closely watch the clutch master cylinder. my bet is you will see it move quite a bit due to a cracked firewall.

 

That's another good possibility, this old truck does have its share of road cancer. If that is it, what are some fixes for it?

 

Apparently the firewall is a pretty common problem, I found this:

http://www.terrapinmfg.com/display.php?prod=14

 

yup, there was an update by ford to install a reinforcement plate not quite that beefy back in the day, but it was canceled around 1995.
that terrapin unit is much stouter than the one ford first offered.