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1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks
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clutch pedal switch problems

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  #1  
Old 05-05-2009, 09:45 AM
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tpolley
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clutch pedal switch problems

over the last year or so i've had to push the clutch pedal harder and harder to engage the clutch pedal switch so i can start my truck. now i have to push as hard as i can on the clutch to engage the switch. is there any way i can fix this?? i've tried messing with the switch. it seems that it moves freely on the master cylinder push rod. if i push it all the way forward (towards the firewall) it has a springyness to it. it has about an inch and a half of free play. i have no idea how this thing is supposed to work. is it supposed to have a home position? is there something that gets tweaked on these cluch pedal assemblies? surely the switch isn't bad.
 
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Old 05-05-2009, 11:12 AM
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On my 88 f350 I found the bracket/arm which the arm/rod to the master cylinder was worn, I replaced the flat bracket/arm and got a new nylon bushing which holds it tightly on the pin and the extra free play went away, my switch is bypassed, not one the wiser moves by the prior owner and I am just too lazy to hook it back up, but it is only me driving it. Look underneath above your gas pedal for loose parts in the pedal assembly.
good luck
 
  #3  
Old 05-05-2009, 05:23 PM
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Definitely check the pedal shaft bushings as lostinfords suggested. It seems pretty common for the master cylinder push rod bushing to pop off the cross-shaft lever arm, which prevents the clutch from getting the full stroke.
 
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Old 05-05-2009, 08:58 PM
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Mine did this, brand new everything. I got tired of having to mess with the clutch to start the truck, but didn't want to disconnect it. What I did was use a small hose clamp and put it on the shaft before the switch, kinda making it think the clutch is pushed in further than it is. It works, and my truck starts every time now. I know it's not the "right" way but it works better than reaching under there so the truck will start.
 
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Old 03-10-2015, 02:39 AM
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I had the same issue. I found that the firewall that the master cylinder bolts to had come detached from the other part of the firewall. Threw some washers on the nuts under the dash. Problem fixed
 
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