My clutch pedal operating rod popped out of the clutch master cylinder pushrod, again, and I bought a new bushing. The old bushing didn't have any locking tabs,they either wore off or were cut off, the new one has locking tabs. I can't get the eye of the pushrod back over the operating rod with the new bushing installed no matter how hard I push and am afraid I am going to break the pushrod. I greased the tabs, no luck. So I put the old worn bushing back on, fabbed a clevis pin out of a paper clip, and pinned the operating rod to the master cylinder rod with a convenient hole.

Does anyone know how to put these parts together like they are supposed to go?

 

The bushing in question should be installed in the pushrod hole first, then snapped over the stud on the operating lever. To be honest, they don't hold that well, because it's just those little plastic tabs keeping the pushrod from slipping off. I've learned to snip the tabs off, and use a washer and a circlip on the groove in the op lever stud. The setup you described sounds like it works well too.

Sometimes the bushing pops off because the clutch pedal cross shaft bushings are worn, and the shaft can wiggle back and forth a little.

 

Thanks I'll try again