F 250 2WD Super Duty V8-7.3L DSL Turbo VIN F (1999)
27.
Align the switch to the tab protruding from the master cylinder which positions the wiring connection at 1 o'clock on pre-February 1998
production vehicles and at 12 o'clock on those vehicles produced after January 1998.
CAUTION
ALIGN THE SWITCH TO THE TAB ON THE FACE OF THE MASTER CYLINDER WHEN THE SWITCH IS REINSTALLED - RISK OF
DAMAGING SWITCH AND INSUFFICIENT PEDAL TRAVEL.
28.
Twist and lock the slave cylinder into the transmission.
29.
Realign the hydraulic line to the clips on the floor pan and dash.
30.
Proceed to slowly depress and release the clutch pedal 5 to 10 times to allow any additional air to bleed from the hydraulic system.
31.
Recheck to assure the hydraulic reservoir is full.
Verify that the low clutch pedal engagement has been fixed by checking the clutch engagement point on the repaired vehicle (assuming vehicle is
unloaded and on level ground):
1.
Start the engine with the transmission in Neutral.
2.
Move the shift control to 1st gear location.
3.
Slowly release the clutch pedal from the down stop until vehicle creeps/starts to roll.
4.
Measure this point down to the stop; this travel should be at least 44 mm (1.75").
If the amount of pedal travel to engagement is less than 44 mm (1 75"), proceed to bleed additional air from the hydraulic system:
1.
Remove the slave cylinder from the transmission case.
CAUTION
DO NOT STROKE (DEPRESS) THE CLUTCH PEDAL WITH SLAVE CYLINDER REMOVED FROM CLUTCH HOUSING - RISK OF
PUSHING PISTON OUT OF CYLINDER.
2.
Unclip hydraulic line from the floor pan.
3.
Straighten out the hydraulic system so that the slave cylinder rod opening is facing down and the hydraulic line is routed up toward the master
cylinder so that there are no "high points" in the system to prevent air bubbles from rising through the system to the fluid reservoir.
4.
Verify the fluid reservoir is full during this bleed procedure to prevent air from entering the hydraulic system. Be sure there are no high points to
trap bubbles.
5.
Push the slave cylinder pushrod fully into the slave cylinder, bottoming the piston, to force air out of the slave cylinder and into the hydraulic line.
Hold fully bottomed for 5-10 seconds to allow all bubbles to rise through the system.
6.
Very slowly, so air is not drawn back into the slave cylinder, release the push rod (the spring in the slave cylinder will force the piston outward).
7.
Wait 5-10 seconds for the bubbles to rise.
8.
Repeat Steps 5 through 7 until all air is expelled from the system (watch for air bubbles at the fluid reservoir).
9.
Twist and lock the slave cylinder back into the transmission.
10.
Once the slave cylinder is back in place, slowly depress and release the clutch pedal 5 to 10 times to bleed any air bubbles still trapped to the
clutch fluid reservoir.
NOTE
IF YOU EXPERIENCE A REPEAT LOW CLUTCH CONCERN ON 1999 F-SUPER DUTY WITH 7.3L/M60D AND ARE HAVING
PROBLEMS WITH BLEEDING AIR FROM THE CLUTCH HYDRAULIC SYSTEM, INSPECT FOR PREVIOUS REPAIR ON THE
FOLLOWING: 1) CLUTCH LINE BETWEEN THE MASTER CYLINDER AND SLAVE CYLINDER FOR A HOSE DAMPER, AND 2) A NEW
CLUTCH PEDAL (F81A-7B633-BC EMBOSSED ON LH SIDE OF PEDAL SUPPORT BRACKET).
IF THE LINE DOES HAVE A HOSE DAMPER, REPLACE IT WITH A NEW CLUTCH HYDRAULIC LINE (F81Z-7A512-BA) PER THE
PROCEDURE DESCRIBED WITHIN THIS TSB. IF THE NEW PEDAL HAS NOT BEEN INSTALLED, OBTAIN A NEW CLUTCH PEDAL
ASSEMBLY (F8lZ-7B633-BC) AND PUT THE NEW PEDAL INTO THE VEHICLE.
