OverlandCamper
New member
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- Jan 11, 2021
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I have a 97 F-250HD, description in signature.
About a year ago, my E4OD went out on me so I swapped it to a ZF-5 S42 I happened to acquire 6 months prior. After the swap, it was running great for a while, then I had the first of three clutch master/slave cylinder failures. The first one was my fault for being dumb and the clutch fork wound up rubbing on the steel braided line and wore the internal liner out and caused it to leak. that lasted from April until August of this year. I swapped out to a whole new pre-bled unit with steel master cylinder from O'Reilly's and did the replacement in a hotel parking lot. Everything seemed fine, drove it about 7k miles then it suddenly went to the floor and no pressure at all. That lasted from about August until last week. Got another from NAPA with a plastic master cylinder, also pre-bled and popped it in. That lasted a week and now it goes straight to the floor and doesn't engage.
To note, I did use the same bellhousing spacer plate from the E4OD to swap the ZF-5. Not sure if that makes any difference but it seemed to work great until my first blow out and even all subsequent runs. No indication of any gradual failure on this last one either, it just had pressure and then it didn't.
When I did the ZF-5 swap, I did buy a brand new pedal assembly (actual Ford setup, from Amazon) and the little peg for the clutch master rod wasn't on, I had to guess and tighten it myself onto the splines. I also went ahead and did the heim joint mod before I stuffed it under the dash to save headaches. When I cut the rod to length, I did note I had to push the pedal in slightly before I could get the heim joint to reach the rod for the master cylinder bore.
would either of these cause an issue with the clutch master cylinder? Like, would the rod push too hard into the bore and blow the seals out? Alternatively, would being too shallow of a push on the Clutch master cylinder cause any issues?
About a year ago, my E4OD went out on me so I swapped it to a ZF-5 S42 I happened to acquire 6 months prior. After the swap, it was running great for a while, then I had the first of three clutch master/slave cylinder failures. The first one was my fault for being dumb and the clutch fork wound up rubbing on the steel braided line and wore the internal liner out and caused it to leak. that lasted from April until August of this year. I swapped out to a whole new pre-bled unit with steel master cylinder from O'Reilly's and did the replacement in a hotel parking lot. Everything seemed fine, drove it about 7k miles then it suddenly went to the floor and no pressure at all. That lasted from about August until last week. Got another from NAPA with a plastic master cylinder, also pre-bled and popped it in. That lasted a week and now it goes straight to the floor and doesn't engage.
To note, I did use the same bellhousing spacer plate from the E4OD to swap the ZF-5. Not sure if that makes any difference but it seemed to work great until my first blow out and even all subsequent runs. No indication of any gradual failure on this last one either, it just had pressure and then it didn't.
When I did the ZF-5 swap, I did buy a brand new pedal assembly (actual Ford setup, from Amazon) and the little peg for the clutch master rod wasn't on, I had to guess and tighten it myself onto the splines. I also went ahead and did the heim joint mod before I stuffed it under the dash to save headaches. When I cut the rod to length, I did note I had to push the pedal in slightly before I could get the heim joint to reach the rod for the master cylinder bore.
would either of these cause an issue with the clutch master cylinder? Like, would the rod push too hard into the bore and blow the seals out? Alternatively, would being too shallow of a push on the Clutch master cylinder cause any issues?
