Ford Truck Clutch Master Cylinder Mount Repair Guide

Understanding the Issue

This document addresses a common issue found in certain Ford trucks: high clutch effort and hydraulic fluid leaks into the cabin. The problem is typically caused by a separation of the clutch master cylinder reinforcement plate from the dash panel. This separation can lead to reduced clutch master cylinder pushrod travel and misalignment, resulting in hydraulic fluid leaks.

Affected Vehicles

The service bulletin specifically targets the following Ford models:

• Ford Light Truck: 1984-1990 Bronco
• Ford Light Truck: 1984-1990 F-150, F-250, F-350
• 1988-1990 Ford Super Duty models

Inspection and Repair Procedures

Ford provides a comprehensive technical service bulletin (Bulletin No. 90-16-7) that outlines detailed inspection procedures to diagnose the clutch system and the integrity of the dash reinforcement. The bulletin guides technicians and owners through steps to identify the cause of the high clutch effort and fluid leaks.

The recommended solution involves the installation of specific reinforcement kits designed to strengthen the clutch master cylinder mounting area. These kits include:

• Small Reinforcement Kit (1983-1987 models) - Part Number E3TZ-7K509-A
• Small Reinforcement Kit (1988-1991 models) - Part Number E8TZ-7K509-A
• Large Reinforcement Kit (1983-1991 models with severe damage) - Part Number E3TZ-7K509-B

The document also includes procedures for bleeding the clutch hydraulic system, which is crucial after repairs or if air is suspected in the system.