Clutch Pedal Bushing Simple Fix - No Tools Needed!

Pulling out of my driveway this morning, my clutch pedal popped and went straight to the floor (again). Upon inspection, the failure was with the clutch pedal bushing and is a simple and quick fix. In this video I will show you just how simple it is and there are no tools needed! This procedure should be similar on any 1987-2011 Ford and 1992-2010 GM vehicles with manual transmissions.

[@harrybean8466]

You're not a fat ass you are a great person for trying to help people.

[@ChaosGarage]

Hehe thanks

[@phillipthomas6777]

Thanks alot, I could not find anything that addresses this job.I come across this video and I went no further, GREAT Job.

[@ValStilwell]

Thanks for the video - you're right, feeding it through the hole first then snapping it into place is the best way. Gaining access to it is the hardest part of the job.... squeezing under the dash upside down is the challenge, lol.

[@garrettsletten5722]

Thanks a ton man. I couldn’t find a decent video on this and you saved me taking the old truck into the shop. Thanks again!

[@ChaosGarage]

Awesome! I'm glad it helped!

[@brendanspecialk9851]

Really? You couldn't figure this out on your own? I mean, really?!

[@gcflstaff3515]

Wow... Thanks great video, my truck been stuck over at Walmart for the exact same problem...👍👍

[@ChaosGarage]

Hope you got it fixed!

[@lipstick318]

Thank you, much appreciated... Wow, awesome video... More videos please...

[@ChaosGarage]

Thank you!

[@deepbludude4697]

Dude! freaking awesome, My 89 f250 idi has the worse pedal ever, has to go all the way to the deck to engage and still feels like it needs more I'm going down on that biotch, thanks for the clear explanation....

[@ChaosGarage]

Good luck! I hope you don't have a worn out clutch.

[@cricklicklers9382]

Thank you! Great helpful video! And, if I need a new switch - I know how to get the old one off. You da man!

[@ChaosGarage]

+Crick Licklers thanks! Glad I could help!

[@brendanspecialk9851]

What switch? The neutral safety switch is on the other side of the fire wall in the clutch master cylinder. You mean bushing.

[@xaivernelson8022]

Alright so i have a 96 f150 5spd and my clutch went to the floor on my way to work for 3rd shift get off thus morning and that metal rod piece was plastic for me. My set up looks just like yours. What do i need and how would i fix

[@chrisw1940]

I had the same problem stuck in a parking lot. Luckily there was a parts store within walking distance so I was able to buy the new bushing and drive home. Ever since I replaced the bushing it has continued to work its way loose. I have to check it every time I drive it. The push rod for the slave cylinder is plastic. Do you think replacing the push rod would fix the problem? 95 f 150

[@andyhatfield8597]

a five minute video for a 30 second fix. Thanks though. It helped.

[@ChaosGarage]

Some people need context :)

[@thejamesbattonshow]

thank you !

[@ChaosGarage]

You're welcome!

[@seanjonezinstrumentals4827]

HACK: I got a thick metal staple and used it kind of like a cotter pin! Hasn't budged in 6 months so far. I bought the bushing and was a waste of money. I found myself trying to push it back on in traffic every half mile. GET A STURDY METAL STAPLE AND USE PLIERS TO BEND IT AROUND!

[@ChaosGarage]

Nice! That's even easier than what I did on the follow up video. I ended up drilling a hole the shaft and running a cotter pin through it to keep that crappy plastic bushing on. Still working great when I got rid of the truck!

[@brionmiller504]

Well i had the exact same thing happening.... exactly. 60 dollars for a master cylinder for the bar only. Pen body released the old one and popped the new one in just like you said. Thanks for the info

[@ChaosGarage]

Sweet! It's definitely worth $60 to not have to replace that master cylinder!

[@RealmanPwns]

what kind of pen?

[@patriciareynolds2729]

my hanger bushing was also worn out. this would be a big job to remove as the brake/clutch pedal both hang on this. I miked the shaft and ordered a copper bushing from amazon that could be tightened in behind in behind the short arm that holds the plastic bushing.maybe it will hold otherwise the hanger will have come out/ be welded/bushed or new hanger installed if it can be found!

[@ChaosGarage]

Nice...hopefully you don't have to pull it out. The video after this I drilled a hole in the end of the shaft and threw in a cotter pin.

[@RealmanPwns]

Can you tell me what type of pen? flexible plastic bic? hard stiff plastic? metal? (used to remove clutch pushrod)

[@ChaosGarage]

A hard stiff plastic cheapo pen should do.

[@ironwill04]

Can you tell me how much travel that push rod going into the master cylinder has? Looms like 2 inches?

[@ChaosGarage]

That sounds about right from what I remember, I'm not sure I can measure it without trying to get it out again but it should click in place and you shouldn't be able to pull it back out by hand.

[@amandaserena2007]

I so appreciate this video. I'm pretty sure this just happened to me in Starbucks drive-thru. A year ago one shop replaced my neutral safety switch. A few months later I have the same problem. I go into a different shop and they replace my slave cylinder which I believe was bad but a month later I'm having the same problem. I go into the shop that replaced my slave cylinder and try to tell them I'm having the same problem on a part that was just replaced (the neutral safety switch) he doesn't listen, tells me it is my neutral safety switch and replaces it again. A few weeks after that, same issue. I go back to the shop that replaced my slave cylinder and neutral safety switch that I am pretty sure I didn't need and he checks it and puts a new bushing on it like you do here. Later that day, clunk, the bushing breaks. I just squeeze it on there the best I can and say I'll zip-tie it later. Never did and now I lost my clutch pedal. I hope it is just that bushing and I can replace it myself. I should of checked but it is in such an awkward place and it's nighttime. Anyway, just wanted to share how much trouble I've had with this little bushing as well as just in that general area. Thanks so much for the video. Fingers crossed tomorrow morning goes smoothly.

[@ChaosGarage]

Dang, this is awkward to get to but not a hard fix...and a cheap part. For me this fix lasted a day or two and it popped off again. A new bushing may do the trick but I don't think a zip-tie will hold it for long. I did another video right after this one where I drilled a hole at the end of the thing that holds the bushing and put a pin in it because it was just worn down too much. It's been almost a year with no more troubles! Good luck...hope you get it figured out!

[@amandaserena2007]

Chaos Garage Ok thanks. I'll check it out. I'll probably have to drill a hole as well since this just keeps happening. Hopefully my drill is powerful enough. Thanks for the quick reply.

[@ChaosGarage]

+Amanda Gale good luck, hopefully that's all it is!

[@amandaserena2007]

Chaos Garage Hey. I thought I would update you quick. So it seems it is definitely just the bushing not holding. I put a zombie around which held for a half mile. It popped out of place but didn't break, so I just wrapped it in duct tape and that held the next mile to get me home. I'm very glad to be home with it. I'm also very glad you told me the zip tie might not hold because it made me think to grab the duct tape and I would have been a pissy missy only getting it half way home. So thanks so much. I might try the drill thing. Do you know like what kind of cotter pin you used? Where I can get one? I heard you say you used and eighth inch drill bit. I just don't want to screw it up. Do you think duct tape will hold for a while? I'm gonna have to go to a store for a cotter pin. I think the duct tape should hold. Lol. Thank god for duct tape.

[@ChaosGarage]

Home Depot and those types of stores have cotter pins. You don't need a big one, I just used what I had laying around in the shop. Then just use a drill bit of the same size. Just go slow getting the bit started because it is hard to get it to start drilling into a rounded surface. If you got the duct tape to hold getting you home, give it a shot...you know how to pop it back on and tape it up again if you have to! Good luck & let me know how it turns out!

[@brionmiller504]

He was talking about replacing the arm with a piece of pen, like you would on ford fuel lines, I would love to hear more about that, mine was plastic and snapped and I'd like to just replace the arm the way he did

[@ChaosGarage]

Oh yeah to replace the rod, I just took the barrel of an ink pen (the cheaper the better) and cut it open like a hotdog bun. It fit perfectly over the shaft and slid into the cylinder. After some pushing, pulling, and wiggling, I got the fingers to let go of the broken rod. Installing the new one was as simple and shoving it in until it clicked. Hope that helps!

[@brionmiller504]

I'm definately trying that first, thanks

[@ChaosGarage]

No problem! I did it in the parking lot at work so I could get home!

[@agustinvasquez5698]

I have the same problem with my ford ranger 1993 it’s because it’s not right part

[@joannecarreiro155]

I have a 2002 saturn sc2. My problem is the clutch rod will come out of the hole if i accidentally pull the pedal all the up and now my peddle just falls to the floor.. Which now i have to lay on my back on the floor under the steering wheel to see where the hole is to put the rod back in. I feel like if there was a bushing to hold the rod so it can't slide out that this would fix my problem. How would you fix this? Without taking it to a shop and pay some ridiculous price to fix..oh and once i put the rod back in the hole my clutch will work.. HELP.. Thank you JOANNE

[@ChaosGarage]

Hmm take the rod out to measure and find one slightly longer?

[@chiliboom6140]

Great video. So you bought a new clutch master cylinder just for the metal push rod and only switched that out?

[@ChaosGarage]

Yes, it was my daily at the time and the clutch master cylinder was working fine. Unfortunately, I couldn't find just the broken rod on short notice locally.

[@chiliboom6140]

@@ChaosGarage 10-4. Thanks for the quick reply sir. I appreciate your help.

[@Thelegendking-yj4bm]

Is this what I have to replace on my 98 ranger. When I push in clutch the brake pedal goes down also

[@ChaosGarage]

Definitely something to check out and see if the rod popped off.

[@kyleanderson7966]

What did you use to replace the rod?

[@ChaosGarage]

I had to buy the whole clutch master cylinder from auto zone for about $40 if I recall just to harvest the rod from it.

[@mymusings1293]

Do I have to remove anything to access the end of the push rod? My mechanic was able to just reach in to pop the push rod back on, but it came off again almost immediately once I was on the road. I slid under the dash, but can't find it in order to pop in the new one. It's driving me crazy, no pun intended.

[@ChaosGarage]

+My Musings no sir you do not have to remove anything. Just crawl up under the dash amd follow the clutch pedal up and over to the right...the rod is way back there!

[@mymusings1293]

I found it! I had to push aside a ton of wire and look deep inside. I saw the old torn up bushing and went, "Ah hah!" Got my little channel locks, took out the old one and put in the new one. Clutch works! I don't know how much money I saved, but the time it would have taken to drop the truck off at the shop, wait for the truck to be worked on, then arrange to pick it up again was worth it. I figured a shop would have charged right around $100, give or take. I'll post my own video once my phone's charged again. Thanks for replying so quickly, by the way!

[@ChaosGarage]

+My Musings awesome! !!

[@MrJcollie]

Same issues here. bushing wore out twice, used some wire instead of buying another tiny piece of plastic. Well, the wire slipped and stressed the rod - rod snapped. I rebuilt the plastic rod with some tin and plastic metal epoxy putty. Still dont know what to do about the stupid clip. I dont want to buy another clip every four months.

[@ChaosGarage]

Wow that stinks. On the part 2 of this video it slipped off again the next day so I ended up drilling a hole and putting a cotter pin in it. So far 1.5 yrs later it's still holding up. *knocks on wood*

[@shanenorvell4655]

I've done replaced 2 of these and they keep popping off and breaking I currently have it ziptied idk what to do

[@ChaosGarage]

I had the same thing happen. Check out part 2 I did for this. I drilled it and used a small cotter pin. It never came off again. kzbin.info/www/bejne/jJqnmqCums2mrpI

[@VtecdippinBB6siR]

I'm having a problem where my clutch pedal keeps pushing the master out of its space and my clutch panel falls to the floor. If there are no bolts to hold the thing together it literally clips together plastic on plastic... What do I do to fix this design flaw from the factory?

[@ChaosGarage]

hmm I'm not sure about that one. I don't have this truck anymore to take a peak in the area you're talking about.

[@CJSaws]

I was surprised to find out the oem bushing from Ford parts department is only 2 bucks. Also check for excessive wear on the pedal bracket because that wear is usually what allows the pedal enough sideways travel to bind and crush the bushing.

[@ChaosGarage]

I didn't realize it was only $2 from Ford either. I ended up having to drill the end of the rod and put in a cotter pin. It had worn it enough the rod wouldn't stay on even with the new bushing.

[@CJSaws]

I just picked up a complete replacement for the entire pedal assembly because the part of the bracket that holds the little axle both pedals hang from is all egged out on the clutch side and is about to break. This under the dash firewall crap makes me wish I was 2 feet tall.

[@ChaosGarage]

oh yeah tell me about it! under dash work sucks for us bigger fellas :)

[@cashonlyj3469]

Thanks for The Parts # Sure helped.$8.88 at Advance Auto Parts

[@cashonlyj3469]

O forgot to add had to pull seat out to get my BIG But in there hard on a Fat Boy.LOL

[@ChaosGarage]

Sweet, glad I could help...it took a little hunting to get the right part from advance if I recall. And it is an awkward squeeze for the bigger fellas but at least you got it done!

[@stick-itproductions.3307]

Would this work for a 2006 Ford Mustang GT?

[@ChaosGarage]

I'm not familiar with the 06 mustang but if it looks the same, then it should work.

[@VtecdippinBB6siR]

I have literally probably the most bulletproof truck ever built by a company and the clutch pedal keeps falling to the floor!! it's the only problem this things ever given me over 20 years at 416000 miles!

[@ChaosGarage]

416k that's impressive!

[@nikolaishriver7922]

Cool, except what do you do when the new bushing won’t stay on and pops off as soon as you push the clutch just like the old broken one? Yes it’s on all the way, yes the plastic indents are seating into the detent on the clutch pedal itself. As soon as you push the pedal, fucking pops right off. Throwing this out there to see if someone has an answer before I pull the pedals out and put a bolt where this half ass pin is tacked to the pedal. Why ford... why use a two cent piece of plastic to hold this on. You had to go as absolutely cheap as possible while thinking it’s engineering brilliance because of how it works. . Except when it’s not 100% perfectly new and doesn’t work at all.

[@ChaosGarage]

No idea why they use a plastic bushing...but now is the time to watch part 2 of this video! kzbin.info/www/bejne/jJqnmqCums2mrpI

[@vernon8337]

FORD !, GREAT IDEA ! , PLASTIC BUSHING ! I guess a washer and carter key just didn't work that great !

[@ChaosGarage]

Very true. It kept slipping off after this so I ended up drilling a hole for a cotter pin anyway in the 2nd part to this video. It held on then until I eventually sold the truck.

[@vernon8337]

right on MAN, I just got finished fixing my 2000 Ranger abour a hour ago, the switch springs rust away and left rusty slime all over the contacts, install new switch, checked plastic bushing, it was still in good shape, Ranger is back up and running, do have a new ford part bushing in toolbox in case that becomes a issue :)@@ChaosGarage

[@ChaosGarage]

Hope you don't need the spare part for a long time!

[@xaivernelson8022]

So is that rod a part to the master cylinder or slave cylinder

[@ChaosGarage]

+xaiver nelson that rod goes into the slave cylinder

[@xaivernelson8022]

Alright so i have a 96 f150 5spd and my clutch went to the floor on my way to work for 3rd shift get off thus morning and that metal rod piece was plastic for me. My set up looks just like yours. What do i need and how would i fix

[@ChaosGarage]

If the plastic eyelet piece broke on the end of the rod like I was talking about in the beginning of the video, I had to buy a whole new slave cylinder from the local parts store (I think it was like $50 or so) which had the rod in it with a metal eyelet. Ford considers it a "non serviceable part" and doesn't sell just the rod. First I had to remove the clutch safety switch and get it out of the way...not too difficult. To get the broken rod out, I took the cheapest plastic ink pen I could find and cut a slit all the way down lengthwise like a hotdog bun. That allowed me to pop it over the shaft and drive it in the slave cylinder until the metal fingers released the rod and slide it out. From there it was easy as pushing the new rod in until it clicked into place. I'm not sure if it is the same on the 96 but that worked on my 93 and after I drilled and put a cotter pin in it (part 2 of this video), it's been fine for almost a year and a half of daily driving. Hope that helps!

[@xaivernelson8022]

So im just going to need a slave cylinder. Im looking at autozone and the slave cylinder doesnt come with a rod but a master cylinder does

[@ChaosGarage]

Looks like I was mistaken (this was over a year ago when I did this)...the clutch master cylinder looks like the right part. www.autozone.com/drivetrain/clutch-master-cylinder/duralast-clutch-master-cylinder/132444_0_0 It has the rod with the metal eyelet and price looks right from what I can remember.

[@brionmiller504]

I'm more interested about the part ford says isn't serviceable, I believe that's what I have going on

[@ChaosGarage]

+Brion Miller I think that refers to the entire clutch slave cylinder. Fortunately the part isn't that expensive but unfortunately doesn't look like fun to replace!

[@blugods2655]

Well the rod that the plastic piece connects to is totally worn down from being used with a wire and not the plastic piece so the plastic piece isn't doing the job

[@ChaosGarage]

What? On your truck? Sorry I'm confused.

[@brendanspecialk9851]

Unnecessary. Count the days until you need another bushing. An upgrade to get rid of all plastics would be helpful.

[@ChaosGarage]

I could count the days on 1 finger...the next day I drilled the stud and put a cotter pin through it. It ran like that up until it recently went to the junk yard!

[@landonwag9689]

That’s a master cylinder not a slave cylinder

[@jamescourier1545]

Yep! The slave actuates on the clutch side.

[@kennyv6135]

Are there any videos that actually show how to fix what they say. Instead of a mother fuckin 20 minute story about all the other horseshit that means nothing? Asking for a friend