Manual cab-n-chasis shift issues - Ford Powerstroke Diesel Forum
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Old 04-24-2014, 07:07 PM
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Manual cab-n-chasis shift issues

My Cab-n-chasis is very hard to shift into reverse and will hard shift/clunk into first(every so often). It is a manual. Is it a problem in the pedal travel(worn) or something more sinister?
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Old 04-24-2014, 09:37 PM
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Probably the clutch not fully disengaging. Try starting it in first or reverse with the clutch down, and when the idle settles out, lift ever so slightly on the pedal. If it engages very abruptly with just a little pedal movement off the floor, then the clutch isn't fully disengaging. If it creeps as soon as the engine starts, it's def. a clutch disengagement issue.

Suspect list:
* Bushing on the clutch master pushrod eyelet - couple possible fixes for it
* Bushings in the pedal box - Q&D test - rest your right foot very lightly on the brake pedal, then work the clutch pedal with your left foot. If you feel "feedback" through the brake pedal in your left foot, pedal box bushings are bad. $20 at the dealer
* Hydraulics - best fix is a complete master-line-slave kit pre-built pre-bled
* Bent/damaged fork - IIRC, dealer has a new improved version
* Weak pressure plate fingers - new clutch time if it's this

Do you find sometimes the engine won't crank with the key unless you mash way effin' hard on the clutch pedal like you're gonna push it through the cab floor?
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Old 04-25-2014, 05:20 AM
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I will do the test tonight. This is my $2900 truck. It takes no key to start and the truck can start in gear. The clutch pedal goes to the floor to get it to shift.
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