'96 F Super Duty stiff clutch

[willie59]

Back in '09 we purchased a 1996 F Super Duty mechanics truck, clutch was bad. I replaced the clutch with a brand name (don't recall the brand) aftermarket clutch and one piece flywheel as the dual mass flywheel is very expensive.

Put the truck in service, clutch was stiff, very firm pedal. I've been just living with it since, but a couple weeks ago, was in the truck for 4 straight days going to various job sites. By Thur, my left foot was numb, then in pain from depressing clutch pedal.

We have since sent the truck to Ford dealer to have original equipment clutch installed, including dual mass flywheel and matching clutch assy. Pedal is slightly easier, but still firm. I'm concerned it's still going to have an effect on my foot with continued driving.

Anybody got any ideas how to remedy this problem? Different master cylinder or slave cylinder? Some type of inline "booster" for fluid clutch? I have to figure out something or it will get to the point I can't drive the truck to do service calls, which will render the truck worthless to us, and nerve damage to my foot has crossed my mind as well. Thanks for looking.

[k20350]

I have a '96 with a stiff clutch also. Just think its the nature of the beast. When I get in the wifes H3 Hummer I almost drive the clutch pedal through the floor after I drive my truck for a while. I drive truck for a living and the pedal is stiffer on the Ford than my Peterbilt. Also my truck has a new dealer installed clutch in it about 5k miles old.

[willie59]

Yes, seems I'm hearing that from several folks, just the way they are.

Only thing that bugs me...I'm not convinced this truck came off the Ford assembly line with a clutch as stiff as this one, they'd never sell the darn thing, and even if they did, a buyer would bring it back within a week cussing them like a sailor. WTF happened along they way for this clutch to get like this???