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Incomplete clutch release and/or hydraulic fluid leaking into the cab from the clutch master cylinder may be caused by the reinforcement plate on the clutch master cylinder separating from the dash panel. The separation of the reinforcement plate reduces the clutch master cylinder pushrod travel. Reinforcement plate separation can also cause deflection of the clutch master cylinder that results in a misalignment of the pushrod to the clutch master cylinder. Misalignment causes the “O” ring in front of the secondary seal to leak hydraulic fluid. Inspection Procedure 1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5″ (12.7 mm) from the floor. 2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear. 3. If the truck passes these tests, go to the Small Reinforcement Installation Procedure Section of this article. a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever. b. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force for installation, Figure 1. c. If it does not line up correctly, install an adjustable pushrod (except 1988 and later models) or replace the clutch release lever (required on 1988 and later models), cutting a new seat on the cross shaft splines. Release bearing travel and gear grinding noise may indicate the following concerns. ^ If the release bearing is 11 mm or greater and there is grinding of one or two gears only, the concern is probably with the transmission. ^ If all gears grind, the concern may be with the clutch and/or pilot bearing which will need replacing. ^ If the release travel is less than 11 mm, check the clutch hydraulic system for air and bleed as necessary.
Tags : clutch master cylinder, clutch fluid, clutch release, clutch pedal, cross shaft, fluid leaks, plate separation, minimal force, release lever, gear grinding, pushrod, dash panel, hydraulic fluid, ford truck, f 250
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