Great video, just bought a 92 that didn’t run, put a used injection pump on and got it running. Now the clutch barely engages at the very top and will only go 2mph slipping like hell. Gonna go through all these items.
I’m fighting with is problem rn in my 97f 350 and 92 F150 the mechanical/hydraulic clutch system is good minus all of the plastics they used to save on cost. The Heim joint does fix the bushing problem until the main ones in the pedal assembly start to wear. While it’s nice to have a safety switch it just gets in the way, so much easier to bypass it and tie it up out of reach
Yep totally agree. At least on the diesel ZF transmission the slave cylinder is external. I belive on the gas the slave cylinder is internal to the bellhousing.
i used a small flat bar gear puller to depress outward the cutch lever to get the push rod to seat on the lever an the slave body to slide up in its holder. the puller bar i placed inside the holder block as high as i could get it an the puller bolt i screw in until it was was inside of clutch lever an push outward enough to mount slave cyl. had to remove puller bolt out from the flat bar an carefully work the bar out an a few love taps seated valve an holding pin. 1990 f-350 7.3 . After a half a day laying on my back fighting the problem this work for me, 😀
What is the engagement point of your ZF5? I replaced my clutch 15k ago & when I did I didn’t replace my master cylinder & pedal bushings. Just thought it was slipping. So when I finally did the bushings after my master/slave cylinder it got better, but before I did my pedal bushings I think I might’ve hurt it cuz the engagement point changed to further up on the pedal. I think it engages at about 1/2 pedal cold then 3/4 warm. I checked under the inspection cover, & it seems I have plenty of clutch but still kinda nervous.
The pedal on this one engages probably at less than half pedal. The engagement point is lower when you have worn pedal bushings so it makes sense that replacing those moved the engagement up. If it's shifting fine I wouldn't worry too much. If you wanted to you could have some one press the pedal while you look at the clutch release arm under the truck checking for full travel/return
And another good trick with these junk zf5 trans , always go to 2nd gear before shifting to reverse or 1st that will help no grinding , clutch in just quickly 2nd then straight to reverse or 1st try it out
My 1996 7.3 powerstroke grinds going into 2nd and it hates reverse. It seemed to me like my clutch isn't fully disengaging and the guy I bought the truck off of replaced the clutch, slave cylinder, throwout bearing and more. He said before he replaced the slave it would grind 2nd to 3rd and 1st to 2nd and still grinds into 2nd from 1st. He didn't bleed the clutch and slave system, could that be my issue or is does it sound like a synchro?
Another area to check is the clutch/pedal linkage bushings. They are known to develop a ton of slop which can cause those types of issues. If the bushings are good, air in the system can definitely cause reduced clutch travel.
@NotEnoughProjects thank you so much man. I'm probably gonna go pickup the truck today and figure out what's going on myself. The guys I bought the truck off of have been keeping in contact with me so I know they didn't cheap me out on it. Just worried about issues on a truck I spent 8500 on. I previously sold a 2nd gen 12 valve for this thing due to transmission issues with the auto and I hate autos now. The zf5 is new to me. Is there a chance you could make a video for me showing me where to find the clutch bushings and all that. Any troubleshooting tips would be very very helpful man
![ZF5 Transmission [5-Speed] - Complete Guide to the S5-42 and S5-47 for Ford Trucks](/img/n.gif)
Great video, just bought a 92 that didn’t run, put a used injection pump on and got it running. Now the clutch barely engages at the very top and will only go 2mph slipping like hell. Gonna go through all these items.
I’m fighting with is problem rn in my 97f 350 and 92 F150 the mechanical/hydraulic clutch system is good minus all of the plastics they used to save on cost. The Heim joint does fix the bushing problem until the main ones in the pedal assembly start to wear. While it’s nice to have a safety switch it just gets in the way, so much easier to bypass it and tie it up out of reach
Yep totally agree. At least on the diesel ZF transmission the slave cylinder is external. I belive on the gas the slave cylinder is internal to the bellhousing.
i used a small flat bar gear puller to depress outward the cutch lever to get the push rod to seat on the lever an the slave body to slide up in its holder. the puller bar i placed inside the holder block as high as i could get it an the puller bolt i screw in until it was was inside of clutch lever an push outward enough to mount slave cyl. had to remove puller bolt out from the flat bar an carefully work the bar out an a few love taps seated valve an holding pin. 1990 f-350 7.3 . After a half a day laying on my back fighting the problem this work for me, 😀
Good idea! Thanks for sharing
What is the engagement point of your ZF5? I replaced my clutch 15k ago & when I did I didn’t replace my master cylinder & pedal bushings. Just thought it was slipping.
So when I finally did the bushings after my master/slave cylinder it got better, but before I did my pedal bushings I think I might’ve hurt it cuz the engagement point changed to further up on the pedal.
I think it engages at about 1/2 pedal cold then 3/4 warm.
I checked under the inspection cover, & it seems I have plenty of clutch but still kinda nervous.
The pedal on this one engages probably at less than half pedal. The engagement point is lower when you have worn pedal bushings so it makes sense that replacing those moved the engagement up. If it's shifting fine I wouldn't worry too much. If you wanted to you could have some one press the pedal while you look at the clutch release arm under the truck checking for full travel/return
And another good trick with these junk zf5 trans , always go to 2nd gear before shifting to reverse or 1st that will help no grinding , clutch in just quickly 2nd then straight to reverse or 1st try it out
Sincro is toast.
Definitely worn! New clutch hydraulics and linkage did improve it though.
My 1996 7.3 powerstroke grinds going into 2nd and it hates reverse. It seemed to me like my clutch isn't fully disengaging and the guy I bought the truck off of replaced the clutch, slave cylinder, throwout bearing and more. He said before he replaced the slave it would grind 2nd to 3rd and 1st to 2nd and still grinds into 2nd from 1st. He didn't bleed the clutch and slave system, could that be my issue or is does it sound like a synchro?
Another area to check is the clutch/pedal linkage bushings. They are known to develop a ton of slop which can cause those types of issues. If the bushings are good, air in the system can definitely cause reduced clutch travel.
@NotEnoughProjects thank you so much man. I'm probably gonna go pickup the truck today and figure out what's going on myself. The guys I bought the truck off of have been keeping in contact with me so I know they didn't cheap me out on it. Just worried about issues on a truck I spent 8500 on. I previously sold a 2nd gen 12 valve for this thing due to transmission issues with the auto and I hate autos now. The zf5 is new to me. Is there a chance you could make a video for me showing me where to find the clutch bushings and all that. Any troubleshooting tips would be very very helpful man
Where'd you find a pre bled system
I belive I got that one off rockauto.com
What is that part at the beginning of the video called
Sorry I'm just seeing this. I'm guessing you are talking about the heim joint? You can look up ZF5 heim joint and find it
You need to rev match while down shifting
That definitely helps
Easiest solution. remove clutch safety switch.
Yep!
Mine is removed and still has this issue
Great video but thats not a super duty bud.
Thanks! You're correct, it's an F-super duty, precursor to f450