In my 02 I am getting a popping sound and heavy click when I depress the clutch pedal.
It is right under the dash and looks like it is the return spring on the pedal making the sound.
Anybody have the same problem and know of a solution?
I am thinking aerosol white lithiium around the anchor points but am not sure if there is something else involved that's making the click.
Any input would be appreciated.
Scott

 

Best thing to do is to get under the dash with a flashlight, operate the clutch pedal and try and find the source of the noise.

 

If it's the isolation spring making the noise just remove it. The clutch feels a lot better (to me) without it anyways. Don't worry, it's not a return spring, the pedal will still function just fine.

There is also a plastic bushing where the clutch master cylinder pushrod attaches to the pedal assembly. They wear out and can bind up.

 

Mine is also doing that. I thought it might be the neutral safety switch. Maybe i should look.

 

Thanks for the pointers.
Now I need to find a double jointed midget to take a look-see under the dash.

 

If yuo have noticed a difference in the shifting, ie..getting harder to get into reverse or other gears when standing still, it is probably the $7 nylon bushing. It has probably worn out and may be half on and half off the shaft.

If you can, drill a hole through the end of the shaft so you can pin it in place. If yo can keep the nylon bushing on the proper part of the shaft, it will last longer. If it wears out and slides part way off the shaft, you wil get ware on the shaft that will prevent the bushing from staying in place from now on.

The lever with the shaft can be purchased I am told. Will find out tomorrow as I need to replace mine. I have drilled the hole to leep the bushing in place, but it was so worn out before I got the thruck, I will need to replace the entire piece. I am going to drill it so I can put a retaining pin in it from the get-go.

Ford used to make a bronze repalcement, but quit a number of years ago. Now only make nylon repalcement. I wa going through one a week until I drilled the shaft to hold it in palce better.

There is a service bulletin that suggest drilling the hole for a retaining pin.

I am interested in knowing what the trick is to get the lever/shaft off after the bolt is removed.

 

The master cylinder end of the rod has one of those thin metal tab washer deals that locks it into place.....similar to the fuel filter line locks on 80's-90's Ford gassers.

 

Cookie:
I am not interested in the rod to the master cylinder.

I am interesdted in the flat part that has the mounting pin that the shaft w/nylon bushing fits on. The pin is worn so I need to repalce it. Have the piece ordered..$22.50. It is held on with one large bolt. Once the bolt is removed, it still will not come off the shaft from the clutch pedal.

 

the ebay hiem joint for down there works great ive got them on all my trucks works so much better and dosnt wear out.

search powerstroke clutch on ebay....