Auto Repair 1984-90 Ford Bronco High Clutch Effort/ Clutch Fluid Leak – Cracked Mount

Auto Repair 1984-90 Ford Bronco High Clutch Effort/ Clutch Fluid Leak – Cracked Mount

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Issue incomplete clutch release and/or hydraulic fluid leaking into the cab from the clutch master cylinder may be caused by the reinforcement plate on the clutch master cylinder separating from the dash panel. The separation of the reinforcementplate reduces the clutch master cylinder pushrod travel. Reinforcement plate separation can also cause deflection of the clutch master cylinder that results in a misalignment of the pushrod to the clutch master cylinder. Misalignment causes the “o” ring in front of the secondary seal to leak hydraulic fluid. Action inspect the truck and, if necessary, use the following service procedure to install a reinforcement kit.

Inspection procedure 1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5″ (12.7 mm) from the floor. 2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear. 3. If the truckpasses these tests, go to the small reinforcement installation procedure section of this article. 4. If either of the above conditions are not met, check the hydraulic system for air. Refer to the suggested bleeding procedure at the end of this article. 5. Test drive the truck and check for improved clutch release.

6. If there is no improvement, proceed as follows: a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever. B. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force c. If it does not line up correctly, install an adjustable pushrod (except 1988 and later models) or replace the clutch release lever (required on 1988 and later models), cutting a new seat on the cross shaft splines. 7. Test drive the truck again, checking for improved clutch release. 8. If there is no improvement, inspect the truck for adequate release bearing travel. * it should be 11mm or greater for full pedal travel. * pedal travel at the center of the pedal pad should be 6.75″ (171mm minimum) or more, fig. 2 . Fig. 2: clutch pedal travel 9. Release bearing travel and gear grinding noise may indicate the following concerns.

* if the release bearing is 11mm or greater and there is grinding of one or two gears only, the concern is probably with the transmission. * if all gears grind, the concern may be with the clutch and/ or pilot bearing which will need replacing. * if the release travel is less than 11mm, check the clutch hydraulic system for air and bleed as necessary. 10. If the release travel is still less than 11mm, with all of the above items eliminated, proceed as follows: a. Raise the hood, while an assistant operates the clutch pedal. B. Watch the clutch master cylinder for significant deflection. C. Look for the dash reinforcement moving away from the dash, figure 3.