On 1993-1995 Ford F-Series Trucks with 7.3L Turbo Diesels (8th digit of Vin F), owners may experience the clutch pedal pushing to the floor without disengaging the clutch. This could be caused by a leaking clutch hydraulic system, resulting in a loss of hydraulic pressure to the clutch assembly.
Ford has released a TSB Article No. 95-4-9, in this article Ford recommends updated some parts to solve this problem.
Model(s): Ford Light Truck: 1993-95 F Super Duty, F-250, F-350
In Ford’s TSB, they list a point of interest with installing the master cylinder. Ensure there is no excess cowl seam sealer under the mounting surface of the master cylinder. Excess sealer will cause the master cylinder to be slightly mispositioned.
Pedal Pivot Shaft Lever is located on top of the Pedal Assembly, this part repositions the lever on the master for a better stroke.
Installing a new Pedal Pivot Shaft Lever (E7TZ-7A554-A) as follows:
1) Snap the new pedal pivot shaft lever (pin) on the new clutch master cylinder push rod bushing.
2) Install the new pedal pivot shaft lever on the clutch pedal shaft.
3) Install the attaching nut finger tight.
4) Inspect the pedal position to ensure it is against the “up” stop.
5) Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in the lever, which then results in correct positioning of the two (2) part.
After the new parts have been installed, follow the system bleeding procedures to obtain proper clutch function.
1) Using Disconnect Tool (T88T-70522-A), disconnect coupling at transmission by lightly tugging on clutch tube while sliding White plastic sleeve toward slave cylinder. Clean area around reservoir cap. Fill reservoir with DOT 3 brake fluid. Using hand pressure, apply 10-15 pounds to clutch pedal. If pedal is hard, go to step 3). If pedal is spongy, go to next step.
2) Using a screwdriver, open valve of male coupling. Slowly depress clutch pedal to floor and hold. Remove screwdriver to close valve, and release clutch pedal. Ensuring reservoir is full, repeat step.
3) Close reservoir and reconnect coupling. Rapidly depress clutch pedal 5-10 times, wait 1-3 minutes, then repeat procedure 3 more times. Place hose on bleeder screw to prevent brake fluid from entering bellhousing. Loosen bleeder screw and maintain fluid level in reservoir.
4) Fluid and bubbles will flow from hose attached to slave cylinder bleeder screw. Close bleeder screw when fluid stream is free of air bubbles. Ensure fluid level is correct and install reservoir cap.
5) Place light pressure on clutch pedal and open bleeder screw. Maintain pressure until pedal contacts floor. Close bleeder screw while pedal is fully depressed. DO NOT allow pedal to return before bleeder screw is fully closed. Recheck fluid level.
6) Test system operation by starting vehicle, depressing clutch and placing gearshift in Reverse. No grinding should be heard or felt when clutch pedal is within 1/2″ (13 mm) of floor. If noise is heard, check for air in system. Repeat bleeding procedure if necessary.