Join Date: Mar 2000
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Re: H8: Clutch master cylinder??
Yup, I run a Ford master cylinder and slave cylinder.
It was really a pretty easy fabrication, and it has worked great since I 1st installed the 5.0.
The fabrication sounds harder than it is, and pics would be very helpfull, but my digi cam is being borrowed.
In any case here goes my attempt to explain it.
I bought an 86 F250 Master cylinder, and an 86 F150 Slave cylinder.
The master cylinder need to be moved about 1 1/4" outward from the stock location, and down about 1"(to clear the brake master, and its firewall bracketry).
To do this, I had to move the YJ fuse box, and bulk head connectors over about 1 1/2". It was easy enough, I just enlarged the hole where they were located, to where I needed it to sit.
With the stock slave cylinder removed and the hole widened enough to move the fuse box, I simple fabbed up a piece of 1/8 steel plate to cover the area of the old and new locations, then cut out a new hole for the fuse box and connectors, and used a hole saw to drill a hole for the new Ford master. to secure the new sheet of steel to the firewall, I used a combination of rivets in some places, and new and existing bolts in all the logical locations.
The cab side of the fabrication also needs to have some of the clutch bracketry ground away with a side grinder to make enough room for the linkage from the pedal to the master cylinder push rod. I extended the stock clutch linkage at the pedal about 1 1/2", by using a piece 3/4" round stock, and had a freind turn down one side to the same diameter as the stock linkage, and drilled out the other side to slide over the stock linkage. I drilled a hole through the new and old piece while it was assembled and put a cotter pin through the two pieces.
Thats about all there is to it, I hope its understandable.
The clutch has the full, and very familiar stroke, of every other Ford I have owned and driven in my life. It has about a 1/4" of free play before beginning engagement, which I like because I can lightly ride my foot on the clutch, on steep obstacles, without inadvertently slipping the clutch.
The slave cylinder, is a push type, and is attached to the bell housing with the standard F150 bracketry.
The only problem I had, was that the Ford issue hydraulic line from master to slave is made of plastic and has inheirant bends in it, that made it impossible to route the line safely away from my headers. I solved this by taking my melted line down to an industrial hydraulic hose shop, and had them weld the stock ends onto 4' of stainless line(with a 90 degree bend on the slave cylinder end). Once I was satisfied with the new line through thorough testing, I took my other line(that was used to replace the 1st melted line),and I had them fab me up an identical spare. I am happy to say that I have never had to use the spare yet.
Thats about all I can think of.