So that little plastic bushing that attaches the shaft of the Master Cylinder to the Pedal assembly busted on me in my 1995 F150 last week. It's crappy plastic and the Master & Slave are both new as of last Feb so I figured "Get a new one, no big deal". Well I've driven on the new one once since and then I leave the driveway this morning and "POP" there goes the new one. Obviously something is wrong and is causing this problem. I suspect the pedal assembly itself is the problem, but if anyone else has another suggestion, I'm all ears. I will say that the sensor "tube" that the master cylinder shaft goes through has the clip that holds it tight to the firewall broken off of it, although I can't see how that would really cause this.
Thanks

 

Are the pedals and clutch master lined up? Sounds like something is binding and breaking it or possibly you just a faulty part. I was going to suggest if you had it working again, check the firewall and have someone push on the clutch and see if its flexing. Also check the pedals and see if they are flexing or if the assembly is worn through

 

Now that the little plastic bushing is toast, I can push the clutch pedal in and see that when the pedal is pushed in all the way, the push rod is pulling away from the shaft (or the shaft is pulling away from it). I'll have to try looking for deflection in the firewall, I guess, and see if anything is happening there. I haven't removed the assembly yet to see if the hole that the rotating bar goes through has ovalled as I leave in a couple days and won't be back until October so I'm not sure I'll actually have time to do anything with it, but we'll see how packing and the like goes.

 

In calling around to parts places, it doesn't look like the assemblies are available anymore. The dealer has the little "dog-leg" cross-shaft lever pin, but that's it. I'm trying the Pick-A-Part places now, but the pickings are slim and after pulling the part myself, I'm still looking at $170 for a part that may or may not have the same problem. This seems like such a small problem to be causing so much friggin' headache.

 

Ok, new question. I've been trying to find parts to fix my problem. I found this bushing kit (http://www.jegs.com/i/Dorman+Products/326/14041/10002/-1) , but I only know what 1 of the 5 bushings in the kit is for. Anyone willing or able to identify the rest of them?

Thanks

 

Anyone else having problems with the link? Strange picture comes up when I click on it; I had to copy and paste it in my browser.

Sorry, I'm just learning about all this now due to my gears grinding when I put it in 1st and reverse, so I don't have any experience to help you with. A wrench-turning buddy of mine tipped me off to his favorite parts site, and everything I'm searching for on there is way cheaper than the box stores. I'm thinking of getting this same bushing kit from www.Rockauto.com for $3.61. Looks to be way better quality than the Help! brand equivalent others are talking about on here. It's listed as "clutch push rod bushing" under "transmission-manual." If you have any more hard-to-find parts, try there as well. Sorry, that's the only advice I can give. Keep working on it, you'll figure it out.

 

That 5 bushing package is just an assortment of bushings. I bought one a few weeks ago and used the clutch rod bushing and one of the others on the transfer case arm. The rest don't fit anything on my truck. The others may be for the older automatic shift rods.

The people that package those also make a package of heater ***** that contains two different GM ***** and a Ford **** in the same package. When I needed new ***** for my daughter's Grand Am, I had to buy three packages to get enough.

 

On the end where the clutch rod that the master and bushing ride on there is a small hole drilled through it , put a small hair pin ( cotter pin) through the hole and it will fix the popping off, I had the same problem with mine, problem fixed!

 

I managed to get home for a weekend and got it "fixed." There wasn't a hole pre-existing in the shaft, but there's a hole with a hitch pin in it now. Trimmed the retention bushing down so it was only a bushing, put a washer on each side of the clutch rod and drilled a hole for a pin. It's not fixed properly, but it's fine by me for now.