We have a 99 f250 6 speed that has the clutch stuck to the floor. Before I tear into it I want a little re assurance on how to it. Does anyone have any instructions to follow to do this without messing something up. I am getting the prebled kit from Parts Guy ed

 

Set aside at least a good 30 minutes the first time you do this. You'll need a pair of channel lock pliers, a small flat blade screwdriver, and if you're smart, a pair of safety glasses when you crawl under the truck.

Let's start at the bottom. Put on your glasses, grab the channel locks and get under the truck. Grab the slave cylinder with the channel locks and give it a 1/4 turn CCW. Then slowly pull it out of the hole. There's a plastic tip with ears on the end of the rod, so pull it out slowly and put your finger on that plastic cap so it doesn't fall off into the bell housing. (it won't as long as you know it's there).

Now lets get inside the cab and understand that the pedal stays on the floor due to a spring and leverage. That same spring and leverage will cause the pedal to fly up and catch you in the jaw if you bump it, so keep a hand on the pedal or stay clear. With a flashlight you can see the connector slips over a little rod on the side of the clutch pedal with some strange plastic clip holding it in place. Take your screwdriver and slide it in between the rod on the clutch pedal and the plastic clip and just pull the clip off the pedal. It should slide right off.

Last, look under the hood. Grab the back side of the master with channel locks and give it the same 1/4 turn CCW and it will come out of the firewall. Remove the little pins holding the reservoir in place and you're done pulling it out.

Putting it back in is just the reverse. The slave rod is held in place with the things that become the ears on the plastic cap. Leave those alone. The first time you push the pedal after the install, those straps will break and you'll be good.

 

Clutch Master Cylinder and Reservoir

Removal
CAUTION: Remove the entire clutch hydraulic system from the vehicle as an assembly when
installing a new clutch master cylinder assembly (7C522).

1. Disconnect the clutch hydraulic tube from the dash clip.
2. Raise and support the vehicle.

Unlock the push rod bushing retaining clips and separate the clutch master cylinder push rod from the clutch pedal.

7. Remove and discard the push rod bushing (7526).
8. Remove the switch cover, and remove the clutch pedal position switch (7C534) from the clutch master cylinder push rod.
9. Separate the power distribution box from the bracket to gain access to the clutch master cylinder.
10. Unlock and remove the clutch master cylinder from the clutch pedal and support bracket.

Compress and twist the clutch master cylinder clockwise 45 degrees to unlock it from the clutch pedal and support bracket.

Remove the clutch hydraulic system from the vehicle.
Install

Position the clutch hydraulic system in the vehicle.
1. Correctly route the clutch hydraulic tube and attach the clutch hydraulic reservoir to the wiring tray.
2. Install the clutch master cylinder.

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Compress and twist the clutch master cylinder counterclockwise 45 degrees to lock it to the clutch pedal and support bracket.
3. Seat the clutch master cylinder rubber seal to the bulkhead.
4. Route the clutch master cylinder-to-slave cylinder hydraulic tube under the brake booster reservoir.
5. Connect the power distribution box to the bracket.
6. CAUTION: When installed correctly, the flat side of the clutch pedal position switch must face the tab protruding from the clutch master cylinder, and the switch wiring connector must be in the 12 o'clock position. Incorrect installation will damage the clutch pedal position switch and cause insufficient clutch pedal travel.

Install the clutch pedal position switch on the clutch master cylinder push rod, and secure it with the switch cover.
7. Install the new the push rod bushing.
8.

WARNING: The clutch pedal is under spring tension.

Connect the clutch master cylinder push rod to the clutch pedal.

9. Raise and support the vehicle.

10. Correctly route the hydraulic tube and slave cylinder (7A564) to the transmission.
11. Install the slave cylinder (7A564).

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Compress and twist the slave cylinder to lock it onto the transmission.
12. Connect the clutch hydraulic tube to the floor pan clip.
13. Lower the vehicle.
14. Connect the clutch hydraulic tube to the dash clip.
15. Test the system for normal operation.

Hope this helps