Clutch pedal Issue

[CowboyJohn]

My son has a 2015 that I have been driving while he is overseas.

I occasionally have an issue where the the clutch pedal hangs up on something in the assembly. I usually have to let off the pedal and push a little harder to get it to fully engage. It hangs at roughly half pedal.

I can feel it hanging up on something and can sometimes hear a click like it is hitting plastic. It is difficult to get a good view. but I can't see anything loose or misplaced in the pedal area.



Any ideas?

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[Cobra Jet]

It could be a number of things.

The S559 Mustangs have a hydraulic clutch system. Could be throw out bearing going bad, couid be air in the system, couid be low fluid level…

Check this thread:
https://www.mustang6g.com/forums/threads/urgent-check-clutch-line-at-brake-master-cylinder.84132/

It has been found on early S550’s that the clutch pedal box assembly has weak spots resulting in fatigued welds at the pedal. Some M6G Members have experienced an actual cracked or broken weld at the clutch pedal assembly, which causes clutch issues. Check these (2) threads:
https://www.mustang6g.com/forums/threads/clutch-brake-pedal-assembly-removal.104338/page-4

https://www.mustang6g.com/forums/th...-manual-cars-check-your-clutch-pedals.155008/

 

[CowboyJohn]

Thanks for the links. I don't think it is in the hydraulics, but I'll check.

I'll definitely check the pivot weld. It could be hanging up on the bushing.

Anyone have an Ant Man suit I could borrow so I can get underneath and get a good look?

 

[SHOdaddy68]

Thanks for the links. I don't think it is in the hydraulics, but I'll check.

I'll definitely check the pivot weld. It could be hanging up on the bushing.

Anyone have an Ant Man suit I could borrow so I can get underneath and get a good look?

Pulling the pedal assembly is a real PITA. Mine was cracked at the pivot bushing. If yours is the same, it will be visible without removing the assembly. You just have to get under the dash far enough to see it.
Took me about 3 hours to get it out and less than a hour to remove the pedal from the assembly and weld it up. You will probably need new sheet-metal shaft retainers to put it back together.

Good luck!

 

[CowboyJohn]

To update this, I think I have narrowed the issue down the the safety neutral switch keeps popping out of the bracket and interfering with the pedal movement.

When I look pictures of replacements online, I notice that mine is missing a tab. I remember finding some plastic in the floor board.

A replacement switch in on order. I'll update once installed.

 

[SHOdaddy68]

To update this, I think I have narrowed the issue down the the safety neutral switch keeps popping out of the bracket and interfering with the pedal movement.

When I look pictures of replacements online, I notice that mine is missing a tab. I remember finding some plastic in the floor board.

A replacement switch in on order. I'll update once installed.

Yeah, these break pretty easily. Blew mine apart taking the pedal assembly out and had to replace it.

 

[mookieit]

I had a similar problem but on the brake pedal.

The switch was stuck and a replacement fixed it

 

[CowboyJohn]

I'm still going to check for a cracked weld as mentioned earlier.

 

[Johnny Rockit]

Are you doing the repairs yourself? My back hurts just thinking about it.

 

[CowboyJohn]

Yes, it is a pain to get under there. Hopefully the welds are good and I don't have to go down that road. It is difficult enough just to get to the switch.

I have seen a couple of videos on removing and installing the clutch pedal assembly and they don't look like much fun.

 

[CowboyJohn]

Well dammit. I put the new switch in and it seemed better for a little bit, but the issue came back.

Crawled under the dash this evening and was able to see a crack. Guess I'll be getting a workout and removing the assembly to re-weld.

Pics of the old switch and crack attached. (Crack is just above the spring)

 

[Johnny Rockit]

I definitely feel your pain. I wonder if they are all prone to cracking?

 

[SHOdaddy68]

This is a common issue. When I went through repairing mine, I took lot's of pics and filed a complaint with the NHTSA. Maybe if more of us do that it will force Ford to issue a recall.

Another thing to look at while you have the pedal assembly out is the slave hose connection at the brake master. These are known to become loose or were not properly connected at the factory.

 

[CowboyJohn]

I went ahead and filed a complaint on NHTSA.

Maybe it will get to the point of a recall.

 

[CowboyJohn]

Well my back is still feeling the pain of getting the pedal assembly out. I got the clutch pedal re-welded and went ahead and did the brake pedal too. The factory welds were only about 40% around the shaft on both sides.

Today I'm gonna try to reinstall everything.

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