Clutch Pedal Sticking

[IDIBRONCO]

Or could it happen as natural wear progresses or corrosion makes it jump one or multiple splines?

The splines are made when you install a new arm, which doesn't have any splines in it. The arm can't jump splines unless the nut that holds it on wasn't installed tightly enough. The other end of the arm will wear out before the splines do.

 

[Sergey]

The splines are made when you install a new arm, which doesn't have any splines in it. The arm can't jump splines unless the nut that holds it on wasn't installed tightly enough. The other end of the arm will wear out before the splines do.

Thanks for the reminder on details of clutch arm. I own this truck for a very long time and believe that the clutch pedal assembly is factory original, hence the nut you describe is likely tightened at Ford factory in 1985.

What may give a clue to an expert - the issue I describe appeared very gradually over about 7 years and gets worse as time goes by. I told Kirkland Transmission about this and they checked and didn't find anything notable. They checked for possible firewall crack and did not detect any.

Given the age of my truck there aren't much options around to find a trusted mechanic willing to investigate a tricky issue on 40+ years truck knowing that it is an annoyance not failure.

 

[rreegg]

@Sergey I'm only familiar with the bricknose clutch assembly but believe they are comparable to the bullnose. This video below may be worth checking out. Least on the bricknose there are multiple internal bushings on the clutch that can wear through and start wallowing out the aluminum bracket. My assumption without looking at things is the increased friction of a worn through bushing may be causing the slow pedal return.

Maybe you can try spraying a lubricant around there and see if it helps with the pedal return? That may help isolate where the issue lies.The attached pic is an example of a worn out bushing leading to a wallowed out aluminum hole, kind of confusing perspective if you're not familiar with the assembly - this looks like the splined/pushrod side instead of pedal side

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[Sergey]

@Sergey I'm only familiar with the bricknose clutch assembly but believe they are comparable to the bullnose. This video below may be worth checking out. Least on the bricknose there are multiple internal bushings on the clutch that can wear through and start wallowing out the aluminum bracket. My assumption without looking at things is the increased friction of a worn through bushing may be causing the slow pedal return.

Maybe you can try spraying a lubricant around there and see if it helps with the pedal return? That may help isolate where the issue lies.The attached pic is an example of a worn out bushing leading to a wallowed out aluminum hole, kind of confusing perspective if you're not familiar with the assembly - this looks like the splined/pushrod side instead of pedal side

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Thanks! Interesting - the video points to aluminum pedal assembly problem. I thought it could be a growing crack, while in video the issue is of different root cause. You circled it right on the spot. It could be my issue. Either way .... removal (and possibly replacement) of pedal assembly will be required.