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
E3TZ-7A564-A Clutch Slave Cylinder
F2TZ-7A543-D Clutch Master Cylinder
F5TZ-7A512-A Tube Kit
E7TZ-7A554-A Pedal Pivot Shaft Lever
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 pushrod 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) parts.
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 the clutch tube while sliding white plastic sleeve toward the slave cylinder. Clean area around the reservoir cap. Fill the reservoir with DOT 3 brake fluid. Using hand pressure, apply 10-15 pounds to clutch pedal. If the pedal is hard, go to step 3). If the pedal is spongy, go to the next step.
2) Using a screwdriver, open valve of male coupling. Slowly depress the clutch pedal to the floor and hold. Remove the screwdriver to close the valve, and release the clutch pedal. Ensuring the reservoir is full, repeat the 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 the hose on the bleeder screw to prevent brake fluid from entering bell housing. Loosen bleeder screw and maintain fluid level in the reservoir.
4) Fluid and bubbles will flow from the hose attached to the slave cylinder bleeder screw. Close bleeder screw when the fluid stream is free of air bubbles. Ensure the fluid level is correct and install the reservoir cap.
5) Place light pressure on the clutch pedal and open the bleeder screw. Maintain pressure until the pedal contacts floor. Close bleeder screw while the pedal is fully depressed. DO NOT allow the pedal to return before the 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 the clutch pedal is within 1/2″ (13 mm) of the floor. If noise is heard, check for air in the system. Repeat bleeding procedure if necessary.