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TSB 87-16-15 Clutch Pedal Low

LIGHT TRUCK: 1984-87 F-150/350, BRONCO (also applies to '88-96 & '97 >8500GVWR)

ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions.
* Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve.
* Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return.
* Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode.

ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure.

SERVICE PROCEDURE
1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod.
2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop).
3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE:
a. Loosen the clutch pedal attaching nut (left hand side).
b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin.
c. Tighten the clutch pedal attaching nut (left hand side).
d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot. THIS STEP IS REQUIRED!
e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the cross-shaft lever.
NOTE: IF THE PUSHROD IS ALIGNED WITH THE PIN, NO FURTHER ACTION IS REQUIRED.

Cross-Shaft Lever Replacement
Removal
1. Disconnect the master cylinder pushrod from the cross-shaft lever pin.
* (1984-86 Vehicles: Remove the clevis pin. Carefully pull the pushrod from the lever.
* 1987 Vehicles: Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever.
2. Remove the attaching nut.
3. Remove the lever from the cross-shaft, using a pry tool or puller.

Installation
NOTE: THE PROPER POSITION OF CLUTCH MASTER CYLINDER PUSHROD RELATIVE TO THE CROSS-SHAFT LEVER (7A554) PIN IS CONTROLLED BY THIS INSTALLATION PROCEDURE. THERFORE, ONLY THE FOLLOWING STEPS SHOULD BE USED.
1. Install the new lever (pin) to the clutch master cylinder pushrod bushing.
2. Install the lever onto the cross-shaft.
3. Install the attaching nut, finger tight.
4. Inspect pedal position to make sure it is against the "up" stop.
5. Tighten the attaching nut to 50-68 lb-ft (68-92 Nm). This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components.

NOTE: THE ABOVE PROCEDURE IS THE PREFERRED METHOD OF "ADJUSTING" MASTER CYLINDER PUSHROD LENGTH. FREQUENTLY, THE MASTER CYLINDER IS REPLACED OR ADJUSTABLE PUSHRODS ARE INSTALLED TO OBTAIN THE REQUIRED PUSHROD TO LEVER POSITIONING. CROSS-SHAFT LEVER REPLACEMENT IS A MORE EFFICIENT METHOD AND ELIMINATES THE POTENTIAL OF PUSHROD MIS-ADJUSTMENT AND INTRODUCING AIR OR CONTAMINATION INTO THE HYDRAULIC SYSTEM.

CROSS-SHAFT LEVER APPLICATION
Model Year Truck Series Part Number
1984-86 F-Series, Bronco E4TZ-7A554-A
1987 F-Series, Bronco E7TZ-7A554-A

PART NUMBER PART NAME
E4TZ-7A554-A Cross-Shaft Lever
E7TZ-7A554-A Cross-Shaft Lever

OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual

OPERATION DESCRIPTION TIME
SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin 0.4Hr. 6.9L diesel, 0.3 Hr. All others
SP871615B Replace cross-shaft lever (includes time to perform previous alignment) 0.6 Hr. 6.9L diesel, 0.5 Hr. All others

For other TSBs, check here.

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The lever for '83-older mechanical is E1TZ7A554A .
The lever for '84-86 hydraulic is E4TZ7A554A . The bushing is D6TZ7526B .
The lever for '87-97 hydraulic is E7TZ7A554A . The bushing is E69Z7526A .
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TSB 90-16-7 Clutch Cracks Firewall

Publication Date: AUGUST 1, 1990

LIGHT TRUCK: 1984-90 BRONCO, F-150, F-250, F-350
1988-90 F SUPER DUTY


ISSUE: 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.

ACTION: Inspect the truck and, if necessary, use the following service procedure to install a reinforcement kit.

***I MAY ADD THIS LATER - IT'S VERY LONG***
http://www.revbase.com/BBBMotor/TSb/DownloadPdf?id=29116
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TSB 85-05-24 Correction
TSB 85-01-20 Clutch Slow in Cold Weather

Dow 470 brake fluid is marketed under NAPA label/number 45012 (12 oz. container).

WARRANTY STATUS: INFORMATION ONLY

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See also:
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