Clutch Master Cylinder Pushrod Play

['93 W250]

First post, 1993 w250 manual. Done a bit of maintenance in the month I've owned it to include replacing a bad tappet seal, fuel and oil filters, bad fuel shutoff solenoid connectors, etc. Most recently, the retaining pin on the clutch pedal that connects to the pushrod running into the master cylinder broke off. I replaced it with an eclip. That failed too. I figured it was going to by looking at it though, the stud was all beat up. Third time it failed, I pulled the pedal off. The weld for the sleeve had cracked (answered one of my recurring questions about the play in the clutch pedal) and was hanging on by a thread and the stud was in real bad shape. Rewelded that. Cut the old stud off, punched the remainder out, replaced with a bolt and welded that in. Put a nut on the other side and seated it so there was still a little play on the pushrod but it was secure. The push rod had a ton of play in it when I took the connection off the stud. Still has quite a bit of play. Like, i feel like I'm churning butter when I move it around. Is that normal or do I need to replace the master cylinder? There is also an electrical connection down there on the pushrod that the previous owner had removed so it's just hanging loose. Any ideas what that is? Thanks for the help in advance gents.

 

[dodgenstein]

Electrical connection is starter safety switch (prevents starter engagement unless clutch is fully depressed). The eye in the clutch rod will get worn the same as your pedal pin. It can be welded up, bushing installed, or cut off and replaced with a rod end.

 

['93 W250]

Ya I looked at the rod and it's definitely beat up. I plan on replacing it when I replace the clutch but that's a little down the road after a new turbo. My question was more about when I disconnected it from the pedal, it just hung freely and I could move it around in a 3 inch circle. Is that normal or is there a guide that is broken maybe? I've looked at the parts new and don't see anything but just wondering if I missed something. Thanks for the reply.

 

[dodgenstein]

That play is normal. It has to allow for a stationary master cylinder and a pedal end that swings in an arc. Be careful on a wallowed out pushrod hole, I have seen them get to the point of inconsistent disengagement, or complete failure if the clutch is fairly stiff.

 

['93 W250]

Ok awesome, thanks for the help. I'll start looking at some ideas or new parts.

 

[Deathrowdave]

Mine was worn so bad it was ready to be a multiple piece unit . I drilled out the pedal and added a heim joint . I made the push rod that screwed into the heim joint from a spring center bolt . Works as good as new and will out last me now