Fixed ZF clutch issue - ZF driver feedback needed.

JSmall · Mar 30, 2015

dclack said:
X2. I pulled the trans, MC, and line all from the same 1990 F250 and used a new slave cylinder and stock clutch from O'Reillys. Works just as smooth as it did in the truck. However, my brother-in-law, used the same clutch but the MC and line kit from BCs and he is experiencing the same issue you describe. I'd suggest you just grab a used unit from a junk yard and see how it feels.

I would like to do that, but I don't want to drop the transmission to get to the slave. If I would have know there was issues with their setup, I would not have purchased it. Live and learn.

I don't mind spending $50 on a new Wilwood MC if it will fix the issue. Only issue I need to resolve is how to connect the Slave line to the 3/8-24" outlet on the Wilwood MC.

Any suggestions?

dclack · Mar 30, 2015

I meant to just grab a JY MC. I wouldn't want to pull the trans either.

Past_Miner · Mar 30, 2015

JSmall said:
I would like to do that, but I don't want to drop the transmission to get to the slave. If I would have know there was issues with their setup, I would not have purchased it. Live and learn.

I don't mind spending $50 on a new Wilwood MC if it will fix the issue. Only issue I need to resolve is how to connect the Slave line to the 3/8-24" outlet on the Wilwood MC.

Any suggestions?

I am assuming the BC kit requires you to remove the original Ford snap connector at the slave cylinder and install their hose in the housing directly. I haven't ever actuall seen the kit but that's how I understand it works. I can't claim for sure that this adapter has the same end that the hose does but it looks like it is the same:

http://www.ebay.com/itm/84-97-CHEVY-T5-T56-HYDRAULIC-CLUTCH-LINE-FITTING-AN-4-LINE-5-6-SPEED-SWAP-/130992050230?hash=item1e7fbc1036&vxp=mtr

It's expensive but you could put this in the slave and make a braided stainless line with AN fittings that adapt to any ends you like.

JSmall · Mar 30, 2015

dclack said:
X2. I pulled the trans, MC, and line all from the same 1990 F250 and used a new slave cylinder and stock clutch from O'Reillys. Works just as smooth as it did in the truck. However, my brother-in-law, used the same clutch but the MC and line kit from BCs and he is experiencing the same issue you describe. I'd suggest you just grab a used unit from a junk yard and see how it feels.

Past_Miner said:
I am assuming the BC kit requires you to remove the original Ford snap connector at the slave cylinder and install their hose in the housing directly. I haven't ever actuall seen the kit but that's how I understand it works. I can't claim for sure that this adapter has the same end that the hose does but it looks like it is the same:

http://http://www.ebay.com/itm/130992050230?ssPageName=STRK:MESINDXX:IT&_trksid=p3984.m1436.l2649

It's expensive but you could put this in the slave and make a braided stainless line with AN fittings that adapt to any ends you like.

Link won't work for me. The BC kit has the hose already attached to the slave so I didn't mess with that. The hose connection at the MC uses a rubber o-ring and dowel pin to keep it in place. That is the end I would like to modify. If I have to remove the transmission to fix this issue, it won't be going back in.

dclack · Mar 30, 2015

The BC kit uses an OEM style MC, so you should be able to grab one from a JY.

1990 F-series MC - .880" bore
http://www.oreillyauto.com/site/c/d...r_5006500_3707&keyword=clutch+master+cylinder

1995 F-series MC - .709" bore (bottom exit but I'm pretty sure it's the same connection)
http://www.oreillyauto.com/site/c/d...r_5006500_3707&keyword=clutch+master+cylinder

JSmall · Mar 30, 2015

dclack said:
The BC kit uses an OEM style MC, so you should be able to grab one from a JY.

1990 F-series MC - .880" bore
http://www.oreillyauto.com/site/c/d...r_5006500_3707&keyword=clutch+master+cylinder

1995 F-series MC - .709" bore (bottom exit but I'm pretty sure it's the same connection)
http://www.oreillyauto.com/site/c/d...r_5006500_3707&keyword=clutch+master+cylinder

Thank you! I will go this route if I cannot figure out how to adapt the hose to the Wilwood MC. I can't do the bottom exit with the MC mounted in the same spot it is now.

JSmall · Mar 30, 2015

dclack said:
The BC kit uses an OEM style MC, so you should be able to grab one from a JY.

1990 F-series MC - .880" bore
http://www.oreillyauto.com/site/c/d...r_5006500_3707&keyword=clutch+master+cylinder

1995 F-series MC - .709" bore (bottom exit but I'm pretty sure it's the same connection)
http://www.oreillyauto.com/site/c/d...r_5006500_3707&keyword=clutch+master+cylinder

JSmall said:
Thank you! I will go this route if I cannot figure out how to adapt the hose to the Wilwood MC. I can't do the bottom exit with the MC mounted in the same spot it is now.

Actually I think I'll try to make the .709 bottom exit MC work. I might have enough room. The MC I have now is .875 so this should be a decent option. Thanks for the help

dclack · Mar 30, 2015

That bottom exit MC has the rotating base, so you could tilt the reservoir a little if you need the clearance.

JSmall · Apr 4, 2015

Removing the spacer made a big difference in the feel of the clutch. New pushrod is much better than what I had.

I think I'm still going to replace the master to see if it will get even better.

Bronco73 · Apr 5, 2015

Here's my stock replacement MC with the bottom exit.

Past_Miner · Apr 5, 2015

JSmall said:
Link won't work for me. The BC kit has the hose already attached to the slave so I didn't mess with that. The hose connection at the MC uses a rubber o-ring and dowel pin to keep it in place. That is the end I would like to modify. If I have to remove the transmission to fix this issue, it won't be going back in.

Sorry, I seem to be having problems with the hyperlink function here. I think I have fixed the link but it won't be helpful if you want to stay out of the bell housing.

T5 Clutch Fitting

Is the BC hose made of standard teflon lined AN hose or is it something else? If it is AN line you could just cut their connector off and add a hose end and adapter fitting.

It may be worth calling BC and asking them what their line is made from. I haven't called them for years but they have always been helpful in solving these kinds of problems as well. Especially when it involves one of their products.

JSmall · Apr 14, 2015

Follow up

Thanks to this info I was able to fix my issue. I used the 1995 F-Series .709 MC as suggested and now the clutch pedal is 100000% better. Easy to push in, ungages in the middle of the stroke, and I can now feather the clutch.

Not sure why the BC kit doesn't ship with this MC.

Thanks!!!

dclack said:
The BC kit uses an OEM style MC, so you should be able to grab one from a JY.

1990 F-series MC - .880" bore
http://www.oreillyauto.com/site/c/d...r_5006500_3707&keyword=clutch+master+cylinder

1995 F-series MC - .709" bore (bottom exit but I'm pretty sure it's the same connection)
http://www.oreillyauto.com/site/c/d...r_5006500_3707&keyword=clutch+master+cylinder

dclack · Apr 15, 2015

Good deal! I'll have to forward this to my brother-in-law; he has the same issue.

miikee73 · Apr 15, 2015

Good to hear, everyone deserves a break once in a while.

JSmall · Apr 15, 2015

dclack said:
Good deal! I'll have to forward this to my brother-in-law; he has the same issue.

He won't be disappointed. Between removing the spacer and the new MC, it is now fun to drive again.

miikee73 said:
Good to hear, everyone deserves a break once in a while.

This was a big break. I was disappointing with the swap until I got this figured out.

Fixed ZF clutch issue - ZF driver feedback needed.

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