Section 08-00: Clutch System, Service
1996 F-150, F-250, F-350, F-Super Duty Chassis Cab and Bronco Equipped with Manual Transmission Workshop Manual
ADJUSTMENTS

Bearing Travel Measurement, F-Series with 7.3L Diesel and 7.5L Gasoline Engines, External Clutch Slave Cylinder Applications (ZF Transmission)

  1. With the clutch pedal (7519) depressed fully to the floor, measure the external clutch slave cylinder push rod travel.

  1. The push rod should extend 11mm (0.43 inch) minimum. Do not replace the clutch hydraulic system if the measurement exceeds this distance.

  1. NOTE: The clutch slave cylinder must be in place when checking the fluid level. The proper level is indicated by a step on the clutch master cylinder reservoir.

    If clutch slave cylinder travel does not meet the travel requirements check the fluid level in clutch master cylinder (7A543).

  1. Fill to the specified level with Ford High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Do not overfill. The upper portion of the clutch master cylinder reservoir must accept fluid displaced from the clutch slave cylinder as the clutch wears.

  1.  CAUTION: Carefully clean the top and sides of the clutch master cylinder reservoir before opening to prevent contamination of the system with dirt, water and other foreign material. Remove the clutch master cylinder reservoir diaphragm when checking or adding fluid. Carefully replace the diaphragm, cover gasket and cover after filling.

    If the clutch master cylinder reservoir requires any fluid, check the hydraulic system components for leakage.

  1. Remove the rubber boot from the cylinder and check for leakage past the pistons. A slight wetting of the surfaces is acceptable. If excessive leakage is evident, replace the leaking component.