[jstrauss]

OK I just took delivery of this truck today. It's a 2002 F350 CC DRW with the 7.3L and ZF6. I got the truck on the cheap because the clutch won't disengage. I borrowed this truck a few months ago to tow a 33' triple-axle trailer that weighed ~15k lbs and I drove it for almost 400 miles so I feel good about the truck overall. Anyway, I was thinking bent fork or perhaps a bad PP but when I crawled up under the truck, I got a suprise, things did not look like I expected. The ZF6 slave cylinder does not look like the ones I am used to on the ZF5, in fact the fork is completely hidden. I can deal with that, I understand I need to pull the slave cylinder to check the depth to the fork to see if it is bent. How do I get the slave cylinder out? I will be buying Ford manuals for this truck soon but like I said, I just got it today and I am anxious to get it to where I can drive it. Also does anyone know would my truck have the bad design fork, or not? When was this changed? Thanks for any help.

 

[woodnthings8]

Here is the manual for an'02 clutch slave cylinder replacement. The clutch forks after 2000 should have been the strengthened ones.

 

[jstrauss]

OK so I just measured it and it's 3 5/16". I guess I need to do a search on here and see what is the spec.

 

[jstrauss]

The spec I found is 3 1/8". I am not sure that 3/16" could be the difference between working and not working at all, but I drilled an inspection hole underneath as someone else on here suggested and I can see the fork is moving roughly 1/2" or so when the pedal is pushed, so I guess I gotta pull the trans since it appears my hydraulics are working.

 

[jstrauss]

Pulled the trans out last night - the clutch plate is fragged. The rivets that hold it together did not do their job, the whole thing was all in pieces inside the pressure plate. Big surprise there because this thing did not make any noises, I would have expected more rattling with all the loose springs in there.

I found the culprit printed on the pressure plate - "Made In China".

My truck has the new design fork and it looks fine. Time to call PepBoys for a LUK clutch kit.

 

[stairgod]

Same for me last week. Made in china clutch from NAPA. The first time I bent the T/O arm, the clutch rivets were fine, but a spring broke, turned sideways, and the arm snapped in half when I tried to disengage the clutch. Unfortunately with the zf-6, the motto is if in doubt, rip it out(and replace everything!)

 

[Muddinf2501999]

Good info guys. The PDF file is very helpful.

My slave cylinder went out in my '02 today. I just bought a lifetime warranty replacement from O'Rileys since Ford is closed for the holiday weeekend and I need my truck back on the road.

Anyway, I wanted to see if anyone has any bleeding tips for the slave cylinder replacement? I'm about to get started on this thing right now.

Thanks!

 

[klhansen]

I found the culprit printed on the pressure plate - "Made In China".

:icon_mad:

I recently replaced my rear rotors with ones I got at Ford, and they were made there too.

So I've got my fingers crossed.

Anyway, I wanted to see if anyone has any bleeding tips for the slave cylinder replacement? I'm about to get started on this thing right now.

Thanks!

With the tubing hooked up, and the reservoir full on the master cyl, hold the slave cyl with the rod end down, and slooowly stroke the rod in and out. Give it time for the bubbles to rise up to the master cyl reservoir.

Good luck

 

[Muddinf2501999]

:icon_mad:

I recently replaced my rear rotors with ones I got at Ford, and they were made there too.

So I've got my fingers crossed.

Man, I always go out of my way to avoid buying "Made in China" ANYTHING! Sometimes there simply is no other option but I feel your pain.

With the tubing hooked up, and the reservoir full on the master cyl, hold the slave cyl with the rod end down, and slooowly stroke the rod in and out. Give it time for the bubbles to rise up to the master cyl reservoir.

Good luck

Thanks for the advice. After further research and figring out that my clutch master cylinder was actually the culprit, I have decided to buy the pre-bled entire system from Ford on Tuesday.

Also, I found this one at Advanced Auto Parts PN PF9021. $138.00 for master / slave system with lines.

http://shop.advanceautoparts.com/webapp/wcs/stores/servlet/product_Pre-Filled-MST-SLV-Perfection-Clutch_99979028-P_685_R%7CGRP60006_1278711493___#fragment-4

Anyone used this one? (I'm 99% sure its MADE IN CHINA though.....)

Thanks!