'99 zf6 clutch pedal barely disengages at the floor - Ford Powerstroke Diesel Forum
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Old 02-20-2014, 07:52 PM
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'99 zf6 clutch pedal barely disengages at the floor

ok, 99 with 6 speed, clutch pedal has no feel at all for first 3" of travel, spring resistance for next 4" and in the very last inch finally presses and almost fully disengages clutch. i say almost as reverse is damn near impossible to get into as is first unless i shut the truck off.

the reservoir is full.
there does not seem to be fluid leaking externally.
pumping the clutch pedal does not improve the feel/action.
i can also hold the pedal down on level ground in gear without the truck starting to creep.
i attempted to bleed the system with a mity-vac with no change.

i have purchased a new slave cylinder but have not installed it yet, i wanted to see if anybody had any input or suggestions?
thanks.
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Old 02-23-2014, 04:35 AM
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Check for bent clutch fork. Ford has a stronger updated one available.

Sent from AutoGuide.com Free App
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Old 02-23-2014, 08:59 AM
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I pulled the old slave cyl out and stuck my finger in the hole and the clutch fork was only two knuckles deep so I figured it wasn't bent.
I pushed in on the slave cyl and it made all kinds of squidgy noises
I pulled the resivoir off the fire wall and zip tied it to the wire for the hood light to get high spots out of the hose. Pre filled the new slave cyl and got the roll pin started
Knocked out the old roll pin and pulled off the old slave while a buddy kept the resivoir filled and I drained old fluid out then stuffed the line into the new slave cyl.
I slowly worked the new slave at ground level for about 15 pumps till bubbles quit coming out at the resivoir.
Put the new slave into the trans and put the resivoir back on its bracket.
Now clutch releases about an inch above floor instead of on the floor.

Still sometimes hard to get in reverse but I think that's just the trans being a jerk.
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