Clutch pedal

[914x4ctd]

My clutch pedal has a lot of freeplay. It has gotten worse in the last few months. I dissassembled the assy. and found that the pin that the link to the master cyl. rides on has worn almost through. the small plastic bushing is almost gone. Also the big tube that holds pedal on the large pin has a broken weld which would cause the pedal to move side to side. Has anybody else had this problem? Also how can I pull the rod out of the clutch master to remove the switch?

 

[dpuckett]

I, too, had the same problem in my 91, wiht 260xxx mi. GOt to the point that it wouldnt hardly disengage the clutch. I took it all apart, re-welded the broken weld you referred to, making a bead all the way around this time to ENSURE it didnt come undone. THen I filled in the worn part of the horizontal pin, then took a file and trimmed it down so it would fit again. I still have a little slack, but the clutch engages about 2" off the floor now, instead of needing 2" below the floor. I used a stick welder and a 3/32" 6011 rod, set to about 90 amps. Gotta move fast or you'll end up with a bigger mess than you started with. AS for disconnecting the clutch/ starter switch, I cut the wires and clamped them together. Sometimes it is just handier to be able to reach in and turn the key than to get in, sit down, push the pedal, start it, wipe mud, grease, etc off the seat..... But you need to make sure it is in neutral.

 

[914x4ctd]

dpuckett,

That is what I was thinking also. I will try to weld it later tonight. A good friend of mine is a professional welder and he said that we could go to the shop later tonight to try to fix it. I was having a hard time shifting for the last couple thousand miles. Then last week I started having to put the pedal all the way to the floor just to disengage it. My truck currently has about 205k on it now. Thank you for the reply.

 

[914x4ctd]

yes it worked fine. thank you for the help.

 

[Scot]

If the clutch safety switch is the same as the later models, the housing is black and there is a white access plate. There is a latch clip that holds the white plate on and then the rest (black part) slips off of the clutch rod.