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Junkyard Musings and Questions...

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Dyn Blin

Re: Junkyard Musings and Questions...

Excellent idea!

For my long distance motorcycle rides, I long ago learned to zip-tie a fresh clutch cable to the existing one to connect it without having to remove the tank and thread it on the side of the highway.

I don't know why I didn't think of that for the IgM's. Thanks!

Sonoma County,CA
1982 F150 Flareside XLS
NP435 4x4
351W Motorcraft 2150

Rembrant

Re: Junkyard Musings and Questions...

Dyn Blin wrote

Excellent idea!

For my long distance motorcycle rides, I long ago learned to zip-tie a fresh clutch cable to the existing one to connect it without having to remove the tank and thread it on the side of the highway.

I don't know why I didn't think of that for the IgM's. Thanks!

I've actually seen a picture of the stacked ignition module installation. Mr. Reamer on here showed it to me when we met up for lunch a while back. It IS a great idea.

1994 F150 4x2 Flareside. 5.0 w/MAF, 4R70W, stock.
1984 F150 4X2 Flareside. Mild 302 w/ 5spd. Sold.
1980 F150 4X4 Flareside. 300i6 w/ 5spd. Sold in 2021.
1980 F100 4X2 Flareside. 351w/2bbl w/NP435. Sold in 1995

Gary Lewis

Re: Junkyard Musings and Questions...

Administrator

I posted a pic of it some time back, but can't find it.

Gary, AKA "Gary fellow": Profile

Dad's: '81 F150 Ranger XLT 4x4: Down for restomod: Full-roller "stroked 351M" w/Trick Flow heads & intake, EEC-V SEFI/E4OD/3.50 gears w/Kevlar clutches
Blue: 2015 F150 Platinum 4x4 SuperCrew wearing Blue Jeans & sporting a 3.5L EB & Max Tow
Big Blue: 1985 F250HD 4x4: 460/ZF5/3.55's, D60 w/Ox locker & 10.25 Sterling/Trutrac, Blue Top & Borgeson, & EEC-V MAF/SEFI

Rembrant

Re: Junkyard Musings and Questions...

In reply to this post by Gary Lewis

Gary Lewis wrote

David/1986F150Six has one of those cold air ducts. He was trying to sell it at the show but didn't, so contact him.

Hey Gary,

Can you confirm that the air duct David has is the same as the one for my 1984 as pictured?

I have the Ford numbers from David's duct, but I don't have mine to compare to at the moment. (I'm at work).

1986F150Six

Re: Junkyard Musings and Questions...

Administrator

Gary,

E5TE-90675-FA & E3TE-90675-DC

Gary Lewis

Re: Junkyard Musings and Questions...

Administrator

David - Thanks.

Rembrant - Take David's #'s to Fuel Systems/Air Cleaners/Air Cleaner Tube #'s and look in the Description column. (The number on the part is an ID or engineering # that is frequently listed in Description.) And you'll see that E5TE-FA is for an 85/86 351W 4bbl F250/350 with a GVWR over 8500#. Plus E3TE-DC fits 300, 302, 351, and 460 between 1983 & 87.

Gary, AKA "Gary fellow": Profile

Rembrant

Re: Junkyard Musings and Questions...

In reply to this post by 1986F150Six

1986F150Six wrote

Gary,

E5TE-90675-FA & E3TE-90675-DC

Excellent. I'll check mine this evening when I get home to confirm.

Rembrant

Re: Junkyard Musings and Questions...

In reply to this post by Gary Lewis

Gary Lewis wrote

Sounds like you made a haul.

I actually went back to the Pick N Pull today for an extended lunch break...lol. Doesn't everybody go to the junkyard for lunch?...

I grabbed a hydraulic clutch pedal(s) assembly. It was just a few bucks. If I don't end up using it on a future manual trans conversion (or hydraulic clutch conversion), then it will simply be spare parts for the '84. I also grabbed another yoke for the M5OD 5spd, and some other miscellaneous hardware, bolts, etc.

Another item I decided to grab was the plastic guard on the steering box input shaft. This is a nice little black 2pc jobbie, with a bottom plate that fits on the steering box, then the guard fits on the bottom plate. I hadn't seen this style before. The one in my '84 is grey, and is just like a loose upside down bucket that is a real pain to move around because it jams against the frame. (Is my grey one a non-Bullnose piece, or are the both Bullnose pieces from different years?)

Gary Lewis

Re: Junkyard Musings and Questions...

Administrator

If you convert a truck to a hydro clutch I'd recommend using a firewall brace. The Bullnose firewalls were designed for the forces created with a mechanical linkage and are known to flex and may ultimately crack when subjected to the forces from a hydraulic clutch. Ford came out with a reinforcement plate back in the 80's due to that problem, as described in this TSB, but it isn't easily found anymore. However, Terrapin Mfg has one that'll fit our trucks, and I think it is cheap insurance when doing the conversion.

As for the plastic guard, I've never seen a gray one. All the ones I've seen are black. Perhaps the gray one is from a later truck or is aftermarket, I don't know. But it looks like you have a good one with which to replace it.

Gary, AKA "Gary fellow": Profile

Rembrant

Re: Junkyard Musings and Questions...

Gary Lewis wrote

If you convert a truck to a hydro clutch I'd recommend using a firewall brace.

As for the plastic guard, I've never seen a gray one. All the ones I've seen are black. Perhaps the gray one is from a later truck or is aftermarket, I don't know. But it looks like you have a good one with which to replace it.

I actually installed a Terrapin brace in my 1984 when I installed the new clutch master and line, etc. My truck also had the smaller of the two Ford repair braces installed previously...I assume through Ford as part of the TSB some 30 years ago...I dunno really. That Terrapin brace is a lovely piece, well made and plenty strong for the job. I had a bit of an issue with mine as it didn't fit the contours of my cab perfectly. I ended up cutting the angle portion off and then welded it back on at a slightly different angle/location. In any case, it's rock solid now.

Edit: Part of my interest in having these parts on hand is that I'm casually looking for another Bullnose project, and having the parts required for a manual trans swap really opens up my options. Back when I was looking for the truck that I have now, finding one with a manual trans was tough. Furthermore, there seems to be way more early Bullnose trucks for sale up here than later, so finding a complete 84-86 truck or parts truck is not nearly as easy as finding, lets say, a 1980-1981. When I search across the country, there's usually lots of 1980-1982 trucks, and then they taper down hard from there. Most of the time, I don't find any 1985-1986 trucks.

Interesting on the plastic guard for the steering box input shaft. I assume then that mine is from a different vehicle...I dunno. I'll take some pictures of it when I swap them out, which won't happen until I get my new RedHead steering gear and new steering shaft (later this fall I hope).

Gary Lewis

Re: Junkyard Musings and Questions...

Administrator

Now that you mention cutting your brace and welding it back I think I remember that. (Man, what I'd give to be able to remember like I used to. But then, I can't remember how I used to remember.

)

Yes, post some pics of the other plastic guard. I'm curious.

Interesting on finding the later Bullnose. I'm not in the market so hadn't been keeping track. But I'll start watching.

Gary, AKA "Gary fellow": Profile

Steve83

Re: Junkyard Musings and Questions...

Banned User

In reply to this post by Gary Lewis

Gary Lewis wrote

If you convert a truck to a hydro clutch I'd recommend using a firewall brace. The Bullnose firewalls were designed for the forces created with a mechanical linkage and are known to flex and may ultimately crack when subjected to the forces from a hydraulic clutch.

I never observed that when I converted my '83 (with the '82 body/firewall).

I thought firewall flex only affected the later trucks with the ZF trans that had such a strong pressure plate - the one that also cracked the front of the trans. I broke the original mechanical pedal bracket that I had converted to hydraulic after several years, but I never noticed any problem with the firewall.

The only difference I noticed between the '80-83 mechanical & '84-86 hydraulic firewalls was the dimple/hole for the MC, and absence of the hole for the pushrod. That's another reason I don't think converted trucks need a brace, unless they get a trans with a HD pressure plate.

Rembrant

Re: Junkyard Musings and Questions...

Steve83 wrote

I thought firewall flex only affected the later trucks with the ZF trans that had such a strong pressure plate - the one that also cracked the front of the trans. I broke the original mechanical pedal bracket that I had converted to hydraulic after several years, but I never noticed any problem with the firewall.

The only difference I noticed between the '80-83 mechanical & '84-86 hydraulic firewalls was the dimple/hole for the MC, and absence of the hole for the pushrod. That's another reason I don't think converted trucks need a brace, unless they get a trans with a HD pressure plate.

It was noticeable in the firewall of my '84. The seam sealer was split right down the middle, and when the clutch was pressed, you could see the crack open up about 1/16". However, that was only after I removed the original Ford repair brace (the small one). With the brace it was tight. That was with the original 10" clutch, but with only about 35k original miles on it. It was stiff as a brick to push too, so no wonder it put a lot of pressure on the fire wall.

When I installed the new 11" clutch with my 5spd swap, the clutch was soft as butter by comparison.

I thought the original issue was not specifically with the HD ZF clutch, but with ANY clutch once it got worn and the pressure plate and linkages stiffened up. All of that added a lot of pressure on the firewall. I think if a new clutch stayed new "feeling" and soft, it would likely never bother the firewall.

Still, knowing mine was already weakened and cracked (the seam sealer, not the cab) I didn't want to take any chances. The bigger worry to me was water and/or moisture getting in through the crack and causing bigger issues later due to corrosion.

Gary Lewis

Re: Junkyard Musings and Questions...

Administrator

In reply to this post by Steve83

The TSB says it is for 1984-on trucks, but it is really for 1983-on as the 460's and diesels came out in '83 with the hydraulic linkage - and the problems started then, as shown by the master parts catalog entry below. And the TSB doesn't say anything about which transmission the vehicle has. In fact, back on FTE we had lots of people with the problem that hadn't swapped to a ZF, just as Rembrant explained about his.

The issue is the direction of the force that the linkage applies to the firewall as well as how large or small of an area to which that force is applied. The mechanical-linkage clutch pedal is part of a large assembly that bolts on in several places. And the rod goes from the pedal in an almost vertical direction down to the bell crank. So the force is in a vertical direction, and the firewall is very strong in that direction. And, the pedal assembly spreads that force out over a large area.

But the hydraulic master cylinder bolts on in one small spot, which focuses all the force there, and the force is in the fore/aft direction - which is the one where the firewall has its least strength.

Here's the master parts catalog entry for Ford's fix. You can see that there was a small one, E3TZ 7K509-A, and a larger one for "severely damaged" firewalls - E3TZ 7K509-B. Note that both were engineered in 1983, so it seems that Ford knew the problem was going to exist.

Gary, AKA "Gary fellow": Profile

Rembrant

Re: Junkyard Musings and Questions...

In reply to this post by Rembrant

I couldn't help but take a picture of this big old Ford at the pick n pull today...it just looks so weird with the fan exposed.

grumpin

Re: Junkyard Musings and Questions...

Just needs some wings!

Dane
1986 F250HD SC XLT Lariat 4x4 460 C6-Sold
1992 Bronco XLT 4x4 351W E4OD
1998 GMC Sierra SLE K1500 350 4L60E
Arizona

Rembrant

Re: Junkyard Musings and Questions...

grumpin wrote

Just needs some wings!

I know eh? That thing looks like it's 3 ft in diameter...lol.

Gary Lewis

Re: Junkyard Musings and Questions...

Administrator

In reply to this post by grumpin

Yes, it does look like it would take off. But that fan may not be bigger than ours. We just never see them that way?

Gary, AKA "Gary fellow": Profile

85lebaront2

Re: Junkyard Musings and Questions...

Administrator

I suspect that that is a Powerstroke of some version since the fan is normal, not reverse rotation. That would also carry a much bigger radiator and an intercooler.

Bill AKA "LOBO" Profile

"Getting old is inevitable, growing up is optional" Darth Vader 1986 F350 460 converted to MAF/SEFI, E4OD 12X3 1/2 rear brakes, traction loc 3:55 gear, 160 amp 3G alternator Wife's 2011 Flex Limited Daily Driver 2009 Flex Limited with factory tow package Project car 1986 Chrysler LeBaron convertible 2.2L Turbo II, modified A413

Rembrant

Re: Junkyard Musings and Questions...

85lebaront2 wrote

I suspect that that is a Powerstroke of some version...

Yessir, '07 F350 Super Duty diesel.

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