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Article No.
01-24-1

12/10/01

CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT
ABLE TO DISENGAGE CLUTCH - FLUID LEAK FROM
HYDRAULIC CLUTCH LINE

FORD:
2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750

ISSUE
Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or External Slave Cylinder.

ACTION
Check to insure clutch hydraulic line is connected to the Master Cylinder and External Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure for details.

SERVICE PROCEDURE
Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter pins.

NOTE
MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE SAME TIME. VEHICLE LINES
AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND F650-750.

NOTE
VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER) REQUIRE ONLY THE MASTER
CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150.

1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave Cylinder (see previous notes) and the hydraulic line is disconnected or leaking.

2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder, External Slave Cylinder and system bleed procedure.

3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External Slave Cylinder.

4. Remove old quad seal from Master Cylinder and External Slave Cylinder.

5. Install new quad seal in Master Cylinder and External Slave Cylinder.

6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and External Slave Cylinder.

7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External Slave Cylinder).

8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.

Labor Operation Claiming Chart
OPERATION: 012401A
DESCRIPTION: Replace seals and roll pins (includes time to remove and install clutch master and slave cylinders, bleed system and check operation)
VEHICLE: Escape
TIME: 0.9

Parts Block
2C3Z-7C522-AA - Hydraulic Line Roll Pin Service Kit

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

DEALER CODING
BASIC PART NO.: 7C522
CONDITION CODE: 39

OASIS CODES: 505200, 506000
 

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Bulletin No: 05-006/02

Last Issued: 7/8/2002

Subject:
CLUTCH WILL NOT DISENGAGE OR CLUTCH PEDAL REMAINS ON FLOOR

APPLICABLE MODEL(S)/VINs
2001 Tribute
2001 Truck

DESCRIPTION
Some vehicles may exhibit a condition of not being able to disengage the clutch as the clutch pedal is depressed, or the clutch pedal may remain on the floor when depressed. This concern may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder (Truck and Tribute) or external Clutch Slave Cylinder (Tribute only).

REPAIR PROCEDURE
1. Verify customer concern:
- Truck: Verify the roll pin is loose at the Clutch Master Cylinder and/or hydraulic fluid is leaking. (See figure)
- Tribute: Verify the roll pin is loose at the Clutch Master Cylinder and at the external Clutch Slave Cylinder and/or hydraulic fluid is leaking (see figure).


2. Remove the Clutch Master Cylinder and/or the external Clutch Slave Cylinder (Tribute only) according to the Workshop Manual (section 05-10 CLUTCH)

3. Use a 1/8" punch and a small hammer to remove the roll pin(s).

4. Remove the hydraulic filling.

5. Remove the quad seal.

6. Install the new quad seal(s) from the kit.

7. Re-install the hydraulic fitting to the Clutch Master Cylinder and/or Clutch Slave Cylinder:

8. Install the roll pin(s) using the hammer and 1/8" punch.

9. Insert a cotter pin through the center of the newly installed roll pin(s) and bend to secure.

10. Truck: Bench Bleed the Clutch Master Cylinder according to the Workshop Manual (section 05-10 CLUTCH BLEED PROCEDURE BENCH).

11. Reinstall the Clutch Master Cylinder and/or external Clutch Slave Cylinder according to the Workshop Manual (section 05-10 CLUTCH).

12. Bleed the clutch system on the vehicle:
- Truck: The quick connect coupler should make it unnecessary to bleed the clutch circuit on the vehicle, however, if you have clutch apply concerns refer to the Workshop Manual (section 05-10 CLUTCH)
- Tribute: bleed the clutch system on the vehicle according to the Workshop Manual (section 05-10 CLUTCH)

13. Verify repair

PART(S) INFORMATION
Part Number
Description
Qty.
Notes
EC02-FF-460​
Hydraulic Roll Pin Service Kit​
1​
WARRANTY INFORMATION
Warranty Type
A​
Symptom Code
70​
Damage Code
9B​
Part Number Main Cause
EC02-FF-460​
Quantity
1​
Operation Number / Labor Hours:
YY296XRX / 0.9 Tribute
YY297XRX / 1.1 Truck​
Note:
This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.
 
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