DIY Clutch Linkage Repair Instructions - heim joint, bushings - Diesel Forum - TheDieselStop.com
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Power Strokes 1994-1997 Upgrades and Aftermarket Upgrading or adding OEM or aftermarket equipment to your 1994-1997 Ford F-Series with Power Stroke engine.

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Old 10-14-2009, 11:48 PM   #1 (permalink)
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Smile DIY Clutch Linkage Repair Instructions - heim joint, bushings

I recently did my own clutch linkage repair and documented it to share. Rather than using the stock nylon bushing, I modified a 5/8" female rod end heim joint. Its all very solid now and looks like it will last. Its also very servicable should it decide not to last!

Hope this helps someone

www.worldacumen.com/content/clutch.doc
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Old 10-22-2009, 11:50 PM   #2 (permalink)
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Originally Posted by getrolfed View Post
I recently did my own clutch linkage repair and documented it to share. Rather than using the stock nylon bushing, I modified a 5/8" female rod end heim joint. Its all very solid now and looks like it will last. Its also very servicable should it decide not to last!

Hope this helps someone

www.worldacumen.com/content/clutch.doc
Not to rain on your parade but there's a guy who's been selling a "kit" of sorts on Ebay using a cut down rod end like yours, but it's nice to have some intructions/pics too.

I did a similar mod several years ago and also eliminated the switch. More convenient and no close calls so far. Anyway IIRC I used a 3/8 rod end and didn't put a nut on the inside of the arm, just ran the both through both pieces, the rod lined up good this way. I also used a 3/8 bolt for the master rod - drilled a vertical hole in the head the same diameter as the rod, something like 3/16, and welded it, this provided adjustability too. I can take a pic if anyone is interested.
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Old 10-23-2009, 11:51 PM   #3 (permalink)
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I did something similar to this and used an industrial "micro" switch with whisker on it for a neutral safety switch. The original switch is also a redudant cut off for the cruise control so I added a second push button style micro switch for that. Been perfect for about 3 years!
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Old 10-24-2009, 12:22 AM   #4 (permalink)
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i did the same thing on my 1975 f250 when i installed a zf 5 trans and hydrolic's from a f450 back in 1994,,,that was a good truck,shame the kid i sold it to rolled it
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Old 10-27-2009, 04:16 PM   #5 (permalink)
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I looked on eBay, but I couldn't find the kit for sale. I agree that a single bolt would have been better. I just installed a new LuK clutch and SMFW. The pedal now feels as light as my Honda Accord. Very light.

I have yet to test my cruise control! I suspect it will not work. Thanks for pointing this out. Saves me looking in all the wrong places for the problem.
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Old 10-27-2009, 04:39 PM   #6 (permalink)
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Here is a LINK to the one on Ebay.
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Old 11-03-2009, 06:44 AM   #7 (permalink)
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^^^ Yup, that's the eBay one that I used as well.
Works so GOOD that I forgot all about it... 4 years + !!!
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Old 11-03-2009, 12:16 PM   #8 (permalink)
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Here is a LINK to the one on Ebay.
If anyone's interested I have this available for resale. I couldn't use it because I had an aftermarket slave rod with a plastic end. PM me, it'll be cheap.
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Old 09-20-2012, 11:41 AM   #9 (permalink)
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How do u remove that linkage I took the 18mm nut off but linkage is stuck on
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Old 09-20-2012, 12:12 PM   #10 (permalink)
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Are you refering to the clutch pedal linkage arm on the pedal mainshaft? You need to pry it off as it is splined (pressed over the splines when the nut is tightened. Cheers!
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Old 09-20-2012, 02:40 PM   #11 (permalink)
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Ya I tried its really on there and no good place to pry
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Old 09-27-2012, 05:11 PM   #12 (permalink)
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I did mine a little different. I drilled and tapped the pedals (since I did hydroboost too) for UNF bolts, thereby making new studs. Greased the threads, slipped on the master and booster pushrods, and secured them with a nylock nut.

This way I never have to modify the clutch master or booster in case of replacement.

EDIT: btw, I cut a corner off the pedal support so I could properly drill out the old worn-out nub that engages the clutch pushrod.
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DIY Clutch Linkage Repair Instructions - heim joint, bushings-img00485.jpg   DIY Clutch Linkage Repair Instructions - heim joint, bushings-img00493.jpg  
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