My F100 has a clutch in it that currently has only about 8000 miles on it. I have adjusted it to what the shop manual tells me- 1.5inches of free travel in the pedal but it is making a weird noise. When I have the clutch pressed all the way in and have the truck in first or reverse there is occasionally a grinding noise that sounds like the clutch isn't pressed in all the way and the gear is grinding. Its not all the time but is quite frequent. I am not sure what is going on- Throwout bearing, bad clutch, adjustment, tranny problem or something else. By the way its a three speed tranny. Thanks for any advice.

Also in my Ford shop manual right after the clutch adjustment section it talkes about the "Pedal Reserve" What is that talking about??

Thanks
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When you replaced the clutch, did you replace the throw out bearing?
What kind of clutch did you install? Stock, 3 finger design or was it a diaphram type?

As the it makes noise, can you slowly lift the pedal and it quits? Do you feel the it in the pedal(thumping like or such)?

With the pedal pressed(and in gear), nothing is turning in tranny, so likely no issue there. Most likely something with throwout bearing.

 

I just installed a new clutch into my 77 F100 and have some of the same quesitons about free travel. I have had issues in the past adjusting it. Just signing up for the thread.

 

Freightrain:

Its a stock replacement clutch, and yes I did install a new throwout bearing with it. Also, Yes I can feel a throbbing or vibration in the pedal when it is making the noise? What does all that mean???? Thanks

 

I've seen this issue many times. You are correct, 1.5" is about correct for the pedal freeplay. The problem is, your clutch arm (the one from the frame to the block) and linkage component's are worn out. The plastic bushing's in your clutch arm linkage are shot or just plain missing. The proper way is to repair\replace the worn items. The next best thing is to reduce your pedal freeplay until you get around to repairing your worn out clutch linkage. Make your clutch pedal freeplay about a 1/2 inch for now. It would seem that the clutch is not fully being dis-engaged by your description, that is why you are grinding the first and reverse gears from a stopped position.

 

You can get these parts from LMC Trucks for $7/each if your local parts store does not stock them. You'll need 2 of them and I would recommend replacing the felt also.