Is it normal in a 4 spd manual for 1st and 2nd gears to be difficult to shift into? I mean, in my truck, if the clutch pedal isn't resting on the mat, it won't go into gear. Is this something that can be adjusted out, or is the clutch about gone? Truck is an 87 F250 with a 6.9, 4spd on the floor, 4wd, and has 210k miles on it, and I don't know if the clutch is original or has been changed since it was first built.

 

The pedal should be at the top with the master cylinder plunger all the way back.
There is an adjustment arm on the end of the pedal assembly. You will find it clipped on to the push rod that inserts into the fire wall side of the clutch master cylinder.
Check for cracks in the aluminum casting part of the pedal assembly. If cracked adusting the arm is a temporary fix.

You must unfasten the nut on the end of the arm. THen the tricky part is to remove the arm off the splines. You must remove the cover under the steering column. You can use a 6 inch punch and a small hammer ( my favorite tool) and tap it off the end.
You can also lightly tap the nut end of the bar the other direction and the sleeve will help push it off. Dont break the aluminum casting that holds the pedal assembly together. Mine was already cracked when I bought it.

Once removed adjust the pedal up with minimal tension on the master cylinder plunger.
It should not be disengaging the clutch when the pedal is at the top.

I had a clutch not disengage once because the master cylinder had failed also. I had over 200 k on it and still had 25% left on the pad.

Good luck
MF

 

If your master cylinder is fine, carefully check for cracking and flexing in the firewall and the aluminium clutch support bracket.

It it takes very little flexing to cause the pedal to go to the floor without fully disengaging the clutch.

Cracking of the firewall and the clutch shaft support brackets are quite common on many of these trucks.

Seb...

 

Hmmmm...this is interesting. The real kick in the butt is that 3rd and 4th go into gear when the clutch is 2/3 to 3/4 travel of the pedal. It's only in 1st and 2nd that the clutch has to be all the way to the floor.

I'll keep practicing shifting without clutch just in case!!!!

 

Hamberger is right. My clutch support bracket was cracked. Replaced it with a used pedal assembly. Still had to adjust the arm. I suppose the fire wall had bent out some.
Also replaced the dual mass flywheel and clutch kit with a solid flywheel.
No wonder they sold me the truck so cheap.

 

Have someone push the clutch down while you watch the clutch master cylinder.
If it moves very much your firewall is cracked.
Normal is very slight movement, barely noticeable.