RE: Replacing clutch master cylinder on 4000Q

[christopher_bender@fmc.com (CHRISTOPHER BENDER)]

     This guy mentions his problem is that the clutch pedal gets stuck half 
     way down.  Well, I had what I believe to be the same problem, and it 
     has nothing to do with the master cyl.
     
     If you look closely at the spring in the clutch pedal, it has what I 
     call an "over center spring" design.   What it does is for most of the 
     travel, it helps you push down on the clutch pedal.  In the final bit 
     of "up travel," the linkage goes "over center," so that the spring 
     helps to push the pedal back up in that last little bit of travel.
     
     What happened with mine is that the hole for the clevis pin in the 
     pedal wore to an egg shape, so that the "push back" from the master 
     cylinder never got the spring to go over center, so the spring was 
     trying to hold the pedal down, and never got to the point where it 
     helps to lift it up.  If I stuck my foot under it and pulled up, that 
     would make it "pop" over center, but obviously I didn't want to do 
     that.
     
     So the fix is, take the pedal out, weld up the egg shaped hole for the 
     clevis pin, and then redrill it to the proper size.  You probably 
     won't need a new pin and clevis, because they are apparently of a 
     harder material, and they don't wear like the hole in the pedal did.
     
     So, this is my experience.  Maybe this is, or maybe it isn't this 
     guy's problem, but maybe this will be of help to someone.
     
     
     Chris