Questions and Answers

F-350 Clutch Problem Q. Hi, I have a 1994 F-350 with a power stroke and five speed transmission. My problem/question is about 2 years ago I had the slave cylinder crack/burst (leak). At that time I replaced the slave cylinder, line and master cylinder, the truck had approximately 50,000 miles.

Recently it acted up again and I found it to have a leaking master cylinder I replaced it but when I bled it, the rod from clutch pedal to master cylinder will not stay in place, it jumps off the pin on the clutch pedal.

What is the fix for this? Is the dual mass flywheel the cause? Does Ford offer a change over from dual mass to the conventional flywheel?

Thanks,
Neil

A. There was a TSB, 95-4-9. issued on 2/27/95 to fix this. From the bulletin:

Clutch does not disengage - leaking clutch slave cylinder - all diesel engine vehicles

Light truck: 1993-1995 F super duty, F-250, F-350

ISSUE:
The clutch pedal may be pushed to the floor without disengaging the clutch on some vehicles. This may be caused by a leaking clutch hydraulic system, resulting in a loss of hydraulic pressure to the clutch assembly.

ACTION:
Install a new, more robust, clutch slave cylinder and related parts. Refer to the following procedure for service details.

SERVICE PROCEDURE:

1. Inspect the clutch release hydraulic system to determine if the clutch slave cylinder is leaking. If the slave cylinder is leaking, continue to Step 2. If the slave cylinder is not leaking, refer to the appropriate Service Manual for diagnosis procedures.

2. Ensure there is no play or excess wear of the clutch pedal bushings. Replace the clutch pedal bushings if there is any excessive wear.

3. Install a new Clutch Slave Cylinder (E3TZ-7A564-A).

4. Install a new Clutch Master Cylinder (F2TZ-7A543-D) and Tube Kit (F5TZ-7A512-A).

   Note: 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.

5. Install a new Pedal Pivot Shaft Lever (E7TZ-7A554-A) as follows:

   • Snap the new pedal pivot shaft lever (pin) on the new clutch master cylinder push rod bushing.

   • Install the new pedal pivot shaft lever on the clutch pedal shaft.

   • Install the attaching nut finger tight.

   • Inspect the pedal position to ensure it is against the "up" stop.

   • 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) parts.

6. After the new parts have been installed, follow the system bleeding procedures in the appropriate Service Manual to obtain proper clutch function.

Additional Information provided courtesy of ALLDATA