Dash Panel - Cracking At the Clutch Master Cylinder
Article No. 85-9-38DASH PANEL - CRACKED AT HYDRAULIC CLUTCH MOUNTING - (6.9L AND 7.5L) AND FOUR SPEED MANUAL TRANSMISSION
LIGHT TRUCK 1983-84 F-250 HD/F-350
Figure 33 - CRACKED AREA OF DASH PANEL - CLUTCH MASTER CYLINDER MOUNTING:
Figure 34:
Figure 36 - REINFORCEMENT PLATE INSTALLATION TO DASH PANEL:
Dash Panel Cracking at the Hydraulic Clutch Master Cylinder Mounting area (See Figure 33) may be caused by the clutch release bearing binding on the transmission bearing retainer.
Suggested service procedures are as follows:
Repair the cracked area of the dash panel by brazing or fine-wire welding (see Figure 33) and adding a reinforcement plate (see Figure 34) to the inside of the dash panel by riveting the plate in position as shown in Figures 33 and 36. Plate can be made from one piece sheet metal 6.5 inches x 6.0 inches x 0.048 inch thick. Fabricate the reinforcement plate using Figure 34 as a template, clean, prime and finish paint.
1. Remove the instrument panel lower sound insulator assembly.
2. Remove the clutch pedal retention clip.
3. Remove the accelerator pedal.
4. Remove the steering column retainer.
5. Remove the steering column floor plate.
6. Remove the two nuts attaching the clutch master cylinder to the dash panel. Pull the master cylinder into the engine compartment.
7. Remove the stop light switch and brake pedal.
8. Remove the brake booster retention nuts.
9. Disconnect the booster vacuum hose.
10. Remove master cylinder retention nuts and move booster aside.
11. Disconnect ground strap from panel.
12. Remove accelerator cable from panel.
13. Remove mat or carpet to expose the affected area of the dash panel.
Figure 33 - CRACKED AREA OF DASH PANEL - CLUTCH MASTER CYLINDER MOUNTING:
14. Cut insulation pad to position out of way and repair cracks by brazing or fine-wire welding. Grind surface smooth, prime and finish paint. (See Figure 33).
Figure 33 - CRACKED AREA OF DASH PANEL - CLUTCH MASTER CYLINDER MOUNTING:
Figure 34:
Figure 35 - PLATE ATTACHMENT TO DASH PANEL:
15. Using the reinforcing plate as a template, drill seven 5/32" dia. holes in the dash panel and pop rivet the plate in place using 5/32" diameter x 5/16" long standard pop rivets to attach plate to dash panel per Figures 33, 34, and 35. Ream the upper master cylinder stud hole in the dash panel to 15.0 mm dia. per Figure 33.
16. Install accelerator cable.
17. Connect ground strap.
18. Position booster and install master cylinder.
19. Install brake booster retaining nuts.
20. Connect vacuum hose.
21. Install brake pedal and stoplite switch.
22. The increase in dash panel thickness, due to the reinforcement, requires a special hollow stud, to add length to the upper stud of the clutch actuator master cylinder. The procedure to attach the master cylinder to the reinforced dash panel is as follows: (See Figures 23, 24, 25).
23. Jam two 7/16-20 nuts together on stud.
Figure 34:
Figure 36 - REINFORCEMENT PLATE INSTALLATION TO DASH PANEL:
24. Thread N803981 over the upper stud of the master cylinder and torque it to 7-11 ft.lbs. (See Figures 34 and 36).
Figure 37 - ADAPTER STUD INSTALLATION TO CLUTCH MASTER CYLINDER ASSEMBLY UPPER STUD:
Figure 38 - CLUTCH MASTER CYLINDER ASSEMBLY TO DASH PANEL:
25. Remove the two 7/16-20 nuts from N80391.
26. Attach the master cylinder to the dash panel with 7/16-20 nut 37641-S36 and washer 375674- S36 on the upper stud and with nut N620481-S2 (M8-1.25) in the lower stud. (See Figure 38). Torque both to 7-11 ft.lbs.
27. Reinstall mat or carpet (insulation).
28. Install steering column retainer plate.
29. Install steering column bracket.
30. Install accelerator pedal.
31. Install clutch pedal retention clip.
32. Install instrument panel lower sound insulator assembly.
Check the clutch master cylinder operating effort by depressing the clutch pedal. If clutch pedal efforts exceed 40 lbs., remove the transmission and inspect the transmission input shaft bearing retainer (7050) for evidence of galling in the area of contact with the clutch release bearing. If galling is present, the aluminum input bearing retainer should be replaced with a cast iron bearing retainer as outlined below:
1. Remove the transmission from the vehicle as outlined in Section 16-24 of the 1983 or 1984 Light Truck Shop Manual.
2. Inspect the clutch bearing contact area of the input shaft bearing retainer (7050) for galling or gouges. If there are any indications of abnormal wear to the surface of the retainer, discard the retainer and oil seal (7052).
3. Obtain a new cast iron bearing retainer, part number T18-6, and install a new retainer oil seal into the (7050) bearing retainer. Install the retainer assembly to the transmission assembly using a new gasket. Torque attaching bolts to 15-25 ft.lbs.
4. Reinstall the transmission into the vehicle as outlined in Section 16-24 of the 1983-1984 Light Truck Shop Manuals.
PART NUMBER PART NAME CLASS
N803981-S Stud-Hollow S
34671-S8 Nut - 7/16-20 RS
375674-S36 Washer SG
N620481-S2 Nut S
C5TZ-7050-H Retainer Bearing A
S5TZ-7052-A Oil Seal A
8MTH-7051-B Gasket R
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP7050A85
TIME: 4x2 - 5.0 Hrs., 4x4 - 5.9 Hrs. DLR. CODING: Basic Part No. 7050 - Code: 14