Clutch not working correctly after engine replacement.
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Mountain Pass
Joined: Aug 2021
Posts: 123
Likes: 13
From: Atlanta
Clutch not working correctly after engine replacement.
Hey everyone,
I have a 1987 F250 with a 460 and a 4-speed tranny. I just replaced the engine and while I was there, I installed a new clutch, pressure plate, bearings, and resurfaced the flywheel. I just got it fired up earlier today, and I am having issues with the clutch. I am only able to disengage the engine from the transmission when I am literally standing on the clutch pedal. The travel of the pedal feels off, it seems like there is far too much "dead space" in the range of motion, where the pedal is not actually engaging anything. Does anyone have any ideas as to why this could be happening? If so, please let me know.
Thanks!
I have a 1987 F250 with a 460 and a 4-speed tranny. I just replaced the engine and while I was there, I installed a new clutch, pressure plate, bearings, and resurfaced the flywheel. I just got it fired up earlier today, and I am having issues with the clutch. I am only able to disengage the engine from the transmission when I am literally standing on the clutch pedal. The travel of the pedal feels off, it seems like there is far too much "dead space" in the range of motion, where the pedal is not actually engaging anything. Does anyone have any ideas as to why this could be happening? If so, please let me know.
Thanks!
Mountain Pass
Joined: Sep 2009
Posts: 119
Likes: 5
Most likely cause is air in the hydraulic linkage. They can be a bugger to get the last bit of air out.
Next in line would be worn parts in the clutch linkage parts, followed by flex in the firewall (unlikely if it was working before the engine swap.)
Next in line would be worn parts in the clutch linkage parts, followed by flex in the firewall (unlikely if it was working before the engine swap.)
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Joined: Apr 2004
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How much did you take off the flywheel?
I've read several long stories about having to shim the throwout bearing to get it closer to the flywheel after surfacing. If everything else proves out, consider that. The firewall flex is a big item in this era as well.
I've read several long stories about having to shim the throwout bearing to get it closer to the flywheel after surfacing. If everything else proves out, consider that. The firewall flex is a big item in this era as well.
Thread Starter
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Mountain Pass
Joined: Aug 2021
Posts: 123
Likes: 13
From: Atlanta
Truthfully, I have no idea how much the machine shop took off of the flywheel. It was not particularly marred up when I took it in though, so they should not have had to remove much to get a perfectly clean surface. I'd be surprised if firewall flex was the culprit, as the clutch worked 2 weeks ago when I had the old engine in...
Mountain Pass
Joined: Sep 2009
Posts: 119
Likes: 5
I did not undo any hydraulic lines
Not likely that air entered if you didn't open the lines, although I think I remember when I pulled a slave cylinder (still hooked up to lines), the plunger pushed out and I ended up bleeding the system.
I would enlist a helper to work the pedal while you look for slop in the system. Doesn't take much, and maybe combined with flywheel surfacing, is enough to cause your problem.
I'm guessing shimming a throw out bearing will require removing the trans, so I would eliminate all other possibilities first, cause I'm somewhat lazy.
Not likely that air entered if you didn't open the lines, although I think I remember when I pulled a slave cylinder (still hooked up to lines), the plunger pushed out and I ended up bleeding the system.
I would enlist a helper to work the pedal while you look for slop in the system. Doesn't take much, and maybe combined with flywheel surfacing, is enough to cause your problem.
I'm guessing shimming a throw out bearing will require removing the trans, so I would eliminate all other possibilities first, cause I'm somewhat lazy.
Thread Starter
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Mountain Pass
Joined: Aug 2021
Posts: 123
Likes: 13
From: Atlanta
I did not undo any hydraulic lines
Not likely that air entered if you didn't open the lines, although I think I remember when I pulled a slave cylinder (still hooked up to lines), the plunger pushed out and I ended up bleeding the system.
I would enlist a helper to work the pedal while you look for slop in the system. Doesn't take much, and maybe combined with flywheel surfacing, is enough to cause your problem.
I'm guessing shimming a throw out bearing will require removing the trans, so I would eliminate all other possibilities first, cause I'm somewhat lazy.
Not likely that air entered if you didn't open the lines, although I think I remember when I pulled a slave cylinder (still hooked up to lines), the plunger pushed out and I ended up bleeding the system.
I would enlist a helper to work the pedal while you look for slop in the system. Doesn't take much, and maybe combined with flywheel surfacing, is enough to cause your problem.
I'm guessing shimming a throw out bearing will require removing the trans, so I would eliminate all other possibilities first, cause I'm somewhat lazy.
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Cross-Country
Joined: Jan 2017
Posts: 50
Likes: 1
My dad ended up finding the issue. Some sort of bushing had come out of place in the clutch pedal assembly. After he popped it back in and did some adjusting, the pedal works as usual now. Still feels like garbage compared to the cars I am used to driving, but much better than it was haha.
I'd pop the bushing out again and check the pin that it travels on for wear. That part of the assembly is replaceable. If it was run with a bad/missing bushing at some point in the past, that pin may be mis-shapen due to metal on metal contact.
Glad you found the issue, but just being cautious and thinking ahead here...it could be dangerous if it pops out while on the road.
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Joined: Feb 2020
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After a similar experience, I ordered 3 Motorcraft bushings from some Ford dealer out of state. The O'Reilly's bushings I was trying to put in there were absolute crap and popped on me after only a couple days' service. I've had a Motorcraft back in there for almost a year now and it's fine (the other two are in the glove box in case this one fails on the road haha)
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