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Hey all I have a 1991 7.3 with a zf-5 transmission, and the other day i was getting of the highway and the when i depressed the clutch it didnt disengage. I made it home power shifting and there it sits. A few things you should know about it. I can depress the pedal yet its stiffer than before and it wont engage in gears. I can put it in gear before starting it then start it but it makes an awful grinding noise. Any ideas on what is going on.
Check the fluid level in the master. See if there are any leaks from the master down the line to the slave. You need a new slave or master (or both).
Other possibilities include the metal fork that pushes the throwout bearing, it can get worn or bent. And the throwout bearing can get screwed up. This fall when I swapped to 4wd I found out that the throwout bearing was sticking to the quill and took an immense amount of effort to slide along. That and the pilot bearing was shot, causing the input shaft on the tranny to drag and spin even with the clutch pedal down.
So theres a few things to take a look at and report back.
Check the fluid, but if you still have pedal and it is stiffer, the hydraulics are fine.
There is something in a bind (pedal assambly) possible but not likely. You are more than likely going to find a problem with the throwout bearing or pressure plate.
Could be the aluminum piece that holds the pedals under the dash, mine broke, and took me 4 years to notice it. F$%#ed up my reverse because of it, all that time grinding gears for reverse.
The piece cracked, and everytime you press the clutch, the whole assembly under would move preventing the clutch from dissengaging properlly.