F 250 2WD Super Duty V8-7.3L DSL Turbo VIN F (1999)
If the reservoir shows sufficient fluid, then proceed to fix issue by changing the Clutch Hydraulic Line to one without a damper (F81Z-7A512-BA) along
with changing the Clutch Pedal Assembly to one with more travel (F81Z-7B633-BC). Proceed as follows:
Refer to the 1999 Super Duty F-Series Workshop Manual, Pages 308-02-3 through 308-02-10, for reference to the following.
1.
Remove the master cylinder push rod from the clutch pedal assembly pin.
2.
Remove the safety start switch from the push rod by first removing the switch dust cover.
3.
Remove the master cylinder and pushrod assembly from the pedal assembly by compressing and twisting the master cylinder clockwise in the
pedal assembly.
4.
Remove the clutch hydraulic system by removing the reservoir push pins attaching reservoir to the wiring tray.
5.
Twist and unlock the slave cylinder from the transmission.
6.
Remove the line from the floor and dash clips and remove the clutch hydraulic system from the vehicle.
7.
Remove the hydraulic line with the hose damper from the slave cylinder by using a 3/32" punch to drive out the line holding pin and pull the line
from slave cylinder.
8.
Proceed to remove the other end of the line from the master cylinder similar to the slave cylinder by removing the roll pin and pulling the line off.
9.
Remove the pedal assembly from the dash by removing four (4) attaching nuts.
10.
Check to be sure the 0-ring was removed from both the slave cylinder and master cylinder before assembling the new line. If they were not,
remove the old 0-ring.
11.
Obtain the new Clutch Hydraulic Line (F81Z-7A512-BA). Make sure 0-rings/seals are on each end of the line before assembling.
12.
Apply D0T-3 Brake Fluid (C6AZ-19542-AB) to the new line 0-rings/seals and proceed to install new line to the master cylinder and secure with
roll pin.
13.
Hang the system from the reservoir. Straighten out the hydraulic system with the reservoir above the master cylinder and the master cylinder above
the slave cylinder end. Place the slave cylinder end of the line end into a container for waste fluid.
14.
Fill the system by adding DOT-3 brake fluid to the reservoir until the fluid runs out the line where the slave cylinder is to be attached, allowing
fluid to purge air from the system (which takes 2 to 3 fills of the reservoir). Then cap the line.
15.
Prepare the slave cylinder by holding the cylinder so that the port for the line is at the highest point, then fill the extended slave cylinder with fluid.
16.
Remove the line cap and install the filled slave cylinder on the line and secure with roll pin.
17.
Proceed to stroke the slave cylinder slowly by pushing on the end of the slave cylinder pushrod until there are no air bubbles present at the clutch
hydraulic reservoir (5 to 10 times). Push the pushrod until it bottoms out in the slave cylinder each time.
18.
Check the reservoir to make sure system is still full of fluid.
19.
Proceed to install the new Clutch Pedal Assembly (F81Z-7B633-BC).
20.
Install the hydraulic system.
21.
Twist and lock master cylinder to pedal assembly with a 45 degree counterclockwise turn.
22.
Route the hydraulic line from the master cylinder to the reservoir across the front of the lower brake master cylinder taking special notice to not
put loop in the routing high points.
23.
Reinstall hydraulic reservoir to wiring tray with push pins.
24.
Install new Bushing (E69Z-7526-A) to master cylinder pushrod.
25.
Reinstall the master cylinder push rod to the pedal assembly pin.
26.
Install the switch-to-master cylinder pushrod by snapping onto the rod and reinstalling the dust cover.
