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Clutch Pedal Repair

From 1995 Ford F-150 “Ol' Blue” — documented by Steve83.

13 photos 14 videos
1995 Ford F-150 - The clutch engaged too close to the firewall, so before the pedal shaft wore into the steel pedal box, I pulled the pedals down to repair i…The clutch engaged too close to the firewall, so before the pedal shaft wore into the steel pedal box, I pulled the pedals down to repair i… Owner 1995 Ford F-150 - With both pushrods & the steering shaft pushed out of the firewall, the pedal box can come straight down.With both pushrods & the steering shaft pushed out of the firewall, the pedal box can come straight down. Owner 1995 Ford F-150 - With both pushrods & the steering shaft pushed out of the firewall, the pedal box can come straight down. Make sure the clutch & BOO switch…With both pushrods & the steering shaft pushed out of the firewall, the pedal box can come straight down. Make sure the clutch & BOO switch… Owner 1995 Ford F-150 - The assembly comes straight down the firewall, and out into the footwell.The assembly comes straight down the firewall, and out into the footwell. Owner 1995 Ford F-150 - Mark the original lever's alignment to the box, and then back the 18mm nut off until the tip of the threaded shaft is barely recessed.Mark the original lever's alignment to the box, and then back the 18mm nut off until the tip of the threaded shaft is barely recessed. Owner 1995 Ford F-150 - With a prybar on the other end keeping the lever tight to the box, smack the nut's face to drive the shaft's splines out of the lever.With a prybar on the other end keeping the lever tight to the box, smack the nut's face to drive the shaft's splines out of the lever. Owner 1995 Ford F-150 - The spring fork will catch inside the spring, preventing the shaft from sliding too far.The spring fork will catch inside the spring, preventing the shaft from sliding too far. Owner 1995 Ford F-150 - That tiny gap between the shaft & the white plastic bushing is enough to make the clutch move to the bottom of the pedal's travel. If allow…That tiny gap between the shaft & the white plastic bushing is enough to make the clutch move to the bottom of the pedal's travel. If allow… Owner 1995 Ford F-150 - Fortunately, this one hasn't worn into the steel box yet, so all it needs is a replacement (tight) bushing. New replacement bushing kits ([…Fortunately, this one hasn't worn into the steel box yet, so all it needs is a replacement (tight) bushing. New replacement bushing kits ([… Owner 1995 Ford F-150 - I curved the PTFE strip cold by hand enough to fit into the hose clamp, then heated it to tighten the curve, and chilled it to set it. Then…I curved the PTFE strip cold by hand enough to fit into the hose clamp, then heated it to tighten the curve, and chilled it to set it. Then… Owner 1995 Ford F-150 - Using this bolt as a mold makes the bushing rounder than using the hose clamp alone. I preheated the bolt, and heated it longer this time b…Using this bolt as a mold makes the bushing rounder than using the hose clamp alone. I preheated the bolt, and heated it longer this time b… Owner 1995 Ford F-150 - It's tight, but it fits.It's tight, but it fits. Owner 1995 Ford F-150 - I used the stack of washers in the background to pull the splines out of the bushing so I could set the lever back to its mark, and tighten…I used the stack of washers in the background to pull the splines out of the bushing so I could set the lever back to its mark, and tighten… Owner