F 250 2WD Pickup V8-6.9L DSL (1985)
Firewall: Customer Interest
Clutch/Dash Panel - High Effort/Cracking
Article No. 86-20-10
DASH PANEL CRACKS AT CLUTCH MASTER CYLINDER (6.9L(D)/7.5L)
CLUTCH - HIGH EFFORT - DASH PANEL CRACKING/MISSHAPED RELEASE LEVER (6.9L(D)/7.5L)
CLUTCH - INCOMPLETE RELEASE
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DIAGNOSIS (6.9L(D)/7.5L)
LIGHT TRUCK 1983-86 F-250/350
The 6.9L(D)/7.5L clutch systems may exhibit three interrelated durability/performance concerns:
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Dash panel cracking at clutch master cylinder:
This typically is caused by high pedal efforts.
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High pedal efforts:
This typically is caused by binding up of the clutch release lever/throw out bearing/transmission input bearing retainer, or excess wear of the disc.
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Clutch not completely releasing:
This may be caused by several conditions:
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High pedal effort creating system deflections which lower "effective" system travel.
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Restricted pedal travel reduces the ability to fully "stroke" the system.
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Free play in the system can use up some of the pedal travel before the system begins to react.
These conditions are discussed individually in this TSB article. Check the vehicle for all three conditions.
Dash Cracks
Cracks located at the clutch master cylinder should be serviced by installation of a dash panel reinforcement kit (part number 7K509). This kit includes
detailed instructions and parts to mount the reinforcement. When ordering the reinforcement kit, the vehicle should be inspected to determine if stud
extenders will be necessary. If needed, they must be ordered separately.
Check master cylinder studs and determine length of threads currently extending beyond nut. If less than 1/8", stud extenders are required (85-9-38).
When performing the dash panel repair, be sure to:
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Seal dash panel "dish" where service actions have created need, such as welding burn-out of sealant (adjacent to master cylinder).
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Service high pedal effort concerns.
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Adjust pedal freeplay as necessary.
