3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

clutch pedal pulling out of floor!?

Old Jul 7, 2009 | 07:29 PM
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From: Mercury,TX
clutch pedal pulling out of floor!?

Has anyone had this problem? The other day the rod that's connected to the clutch pedal that plunges into the master cylinder popped out as i attempted to push the clutch in to start the truck. Any way to fix this and keep the **** thing from popping out again? I'd sure HATE to have this happen while i'm driving and need to stop suddenly. I had to crawl in the floorboard to put it back in the master cylinder, so I know there'd be no way of being able to use the clutch if this happened while i'm moving and its in gear.
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Old Jul 14, 2009 | 06:16 PM
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I've heard of this happening to others. Surely someone in here might know something about it.
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Old Jul 15, 2009 | 12:07 AM
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From: Whitehorse, cultural hub of the universe..
use a larger thin flat washer, and a proper snap ring to hold the rod onto the pedal boss, instead of that cheesy spring steel rigging that the factory uses.

My 01 did the same thing when it was about 6 months old, I did the repair that I described, and no problems since.
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Old Jul 16, 2009 | 05:25 PM
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From: Mercury,TX
Maybe I should've explained what i mean a little better. The rod come out of the master cylinder itself. I can easily reach down and pull the pedal up and cause it to pop out. I don't like that at all because if I happen to pull my left foot up to push the clutch in and i pull the pedal up when i make this movement, the rod pops out of the firewall.
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Old May 4, 2010 | 08:08 PM
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Mine too

Has anyone got a fix for this mine just did the same thing today while i was coming to a stop light almost creamed a couple cars in front of me.
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