I have a 1995 f-250 7.3L 4x4 stick 222,000 miles. The clutch push rod keeps popping off pedal assemby. Had to replace master two times because it broke the push rod eyelet. I was told the pedal arm could be the problem. I have replaced all bushings in pedal assembly. Any help would be appreciated. Thanks

 

are you repalcing the black clip on the rod???

 

Yes I replaced the bushing every time I changed the master. Upon further inspection I found the clutch pedal assembly arm that connects to the master pushrod is wore out. The surface and the groove that holds the clip on is wore out. Need new arm on clutch pedal assembly. Thanks for you reply and help.

 

We went through this with our 94/95 mid year, we finally gave up and upgraded the master, slave and line. We have had no issues since then other than learning to drive stick all over again seeing as it's alot more responsive than it has been for years. We also stock the nipples for the shaft under the dash as we have found them to go about once a year.

 

A decent fix for worn parts is,,

Cut a small collar out of tubing ect, (check for a good fit I/D and O/D) and slide it on the pin to take up the space in the 'eye' on the pushrod.. Drill the pedal lever pin at the locking groove and use a small cotter pin there.. Apply some grease on the entire assembly going together, and use a small/thin washer against the face of the push rod to protect the cotter pin from 'side load' wearing..