Front End Clunking Noise
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Freshman User
Joined: Jun 2018
Posts: 39
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From: Southeast Michigan
Front End Clunking Noise
Hi all,
Yesterday my truck started to make a clunking/rattle noise whenever I pushed in the clutch at any speed.
Under further inspection, I also realized when I push in my clutch, the whole truck stretches apart-- the engine is pushed forward and right, and the left front fender is pushed out.
The clunk is coming from the firewall area near (above) my feet. I've put a lot of hours researching this problem and getting my hands dirty and can't figure it out.
Any ideas?
Thanks
(I have a 1983 F250 with a mechanical clutch. With the 302 v8)
Yesterday my truck started to make a clunking/rattle noise whenever I pushed in the clutch at any speed.
Under further inspection, I also realized when I push in my clutch, the whole truck stretches apart-- the engine is pushed forward and right, and the left front fender is pushed out.
The clunk is coming from the firewall area near (above) my feet. I've put a lot of hours researching this problem and getting my hands dirty and can't figure it out.
Any ideas?
Thanks
(I have a 1983 F250 with a mechanical clutch. With the 302 v8)
FTE Legend
Joined: Nov 2015
Posts: 30,912
Likes: 4,123
From: Angier, NC
You may want to look over this thread
https://www.ford-trucks.com/forums/1...e-running.html
Check all the pivot points and cross shaft between frame & motor as the plastic bushings fail.
Also I think someoneposted their pedal bracket cracked making noise & moving.
Get a helper to push on the pedal wile you check everything out. On linkage type like yours we have not seen issues with the firewall like the hydraulic setups.
Dave - - - -
https://www.ford-trucks.com/forums/1...e-running.html
Check all the pivot points and cross shaft between frame & motor as the plastic bushings fail.
Also I think someoneposted their pedal bracket cracked making noise & moving.
Get a helper to push on the pedal wile you check everything out. On linkage type like yours we have not seen issues with the firewall like the hydraulic setups.
Dave - - - -
Fleet Mechanic
Joined: Jul 2003
Posts: 1,844
Likes: 129
From: Atlantic Canada
The mounts are all inexpensive....like $10-$15 each.
Tuned
Joined: Dec 2017
Posts: 308
Likes: 8
My truck used to make a series of horrific crunching and creaking noises whenever you'd push or release the clutch.
Also the engine and cab would move away from each other with the force on the pedal.
I looked from underneath the dashboard to find a few big cracks in the zamak (zinc/aluminum) bracket that supports the pedals and steering column.
I got a good one from a junkyard and swapped it in. Fixed most of my issues. Still get some creaks but no more crunching and less flex.
Still might have to do cab and engine mounts to take the play out of the system.
The mechanical clutch setup on these trucks isn't really the best design in the world, but it can be made to work well.
Also the engine and cab would move away from each other with the force on the pedal.
I looked from underneath the dashboard to find a few big cracks in the zamak (zinc/aluminum) bracket that supports the pedals and steering column.
I got a good one from a junkyard and swapped it in. Fixed most of my issues. Still get some creaks but no more crunching and less flex.
Still might have to do cab and engine mounts to take the play out of the system.
The mechanical clutch setup on these trucks isn't really the best design in the world, but it can be made to work well.
FTE Legend
Joined: Nov 2015
Posts: 30,912
Likes: 4,123
From: Angier, NC
My truck used to make a series of horrific crunching and creaking noises whenever you'd push or release the clutch.
Also the engine and cab would move away from each other with the force on the pedal.
I looked from underneath the dashboard to find a few big cracks in the zamak (zinc/aluminum) bracket that supports the pedals and steering column.
I got a good one from a junkyard and swapped it in. Fixed most of my issues. Still get some creaks but no more crunching and less flex.
Still might have to do cab and engine mounts to take the play out of the system.
The mechanical clutch setup on these trucks isn't really the best design in the world, but it can be made to work well.
Also the engine and cab would move away from each other with the force on the pedal.
I looked from underneath the dashboard to find a few big cracks in the zamak (zinc/aluminum) bracket that supports the pedals and steering column.
I got a good one from a junkyard and swapped it in. Fixed most of my issues. Still get some creaks but no more crunching and less flex.
Still might have to do cab and engine mounts to take the play out of the system.
The mechanical clutch setup on these trucks isn't really the best design in the world, but it can be made to work well.
The mechanical linkage you can fix, I have done that, the other system if it fails you have to replace either master or slave then fight to bleed the system and all that is after you checked and / or fixed the firewall cracking.
I will take the old linkage thank you.
Dave ----
Tuned
Joined: Dec 2017
Posts: 308
Likes: 8
That's very true.
I would also keep the linkage over the hydraulic clutch in these trucks, as much pain as it can be.
The clutch linkage may not be the best designed, but the hydraulic linkage seems to cause even more problems.
Plus the mechanical one is manually adjustable so you can adjust out your extra flex.
A mechanical setup from an earlier car when they were more common (including grease fittings, universal or replacement parts, less weird angles and deflection, simpler pedal bracket) would be better,
A hydraulic setup done right (unstressed firewall, simple mechanical parts, external slave cylinder) would also be nice, but on my old truck I like keeping old technology.
I have no plans to swap it! I figure it's better to try and modify/fix it to make it work.
I would also keep the linkage over the hydraulic clutch in these trucks, as much pain as it can be.
The clutch linkage may not be the best designed, but the hydraulic linkage seems to cause even more problems.
Plus the mechanical one is manually adjustable so you can adjust out your extra flex.
A mechanical setup from an earlier car when they were more common (including grease fittings, universal or replacement parts, less weird angles and deflection, simpler pedal bracket) would be better,
A hydraulic setup done right (unstressed firewall, simple mechanical parts, external slave cylinder) would also be nice, but on my old truck I like keeping old technology.
I have no plans to swap it! I figure it's better to try and modify/fix it to make it work.
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Freshman User
Joined: Jun 2018
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From: Southeast Michigan
Thanks all. Will look over the bracket so see if it's that. I will try getting a video of the noise to post.
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Thread Starter
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Freshman User
Joined: Jun 2018
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From: Southeast Michigan
Turns out, the front left cab mount was rusted out. The comes from when I push in the clutch (and the truck hyper extends), the cab no longer sits on the mount, and bangs around.
Not glad to see this. I am either going to run some bolts through or weld a plate over as a short term solution until I can justify lifting the cab.
Thanks for all the help!
Not glad to see this. I am either going to run some bolts through or weld a plate over as a short term solution until I can justify lifting the cab.
Thanks for all the help!
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