How to replace "clutch pedal position sensor/switch" - Diesel Forum - TheDieselStop.com
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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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Old 06-17-2007, 06:14 PM   #1 (permalink)
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How to replace "clutch pedal position sensor/switch"

Folks,

I need some friendly advice on how to replace the "clutch pedal position sensor/switch" (or whatever it is called). The reason I am asking is that...

1) During the last winter, the engine idle would not increase in response to extended idling in cold weather.

2) The other day, I noticed that the truck would start with the clutch predal in the "out" position.

The above got me thinking that the switch might be stuck in the "closed" position, which is fooling the PCM into thinking that the pedal is depressed which would 1) prevent the engine idle from increasing, and 2) allow me to start the truck with the clutch pedal "out".

With all that said, I thought I would just remove the switch, and see if I could get it working again. After looking at the assembly, and reading my service manual, I was still not clear on how to remove it. The manual referrs to a "cover" that can be taken off of the switch, but I am not sure if the switch can then be lifted off of the pushrod (to the master cylinder), or if I have to remove the pushrod from the clutch pedal, and then slide the switch off of the end of the pushrod. I also found it strange that there were so many wires coming off of the switch (I would have expected two), but what do I know about vehcile electronics...

Anyway, if someone can offer advice on how to remove the switch, I would appreciate it. I'd also appreciate any advice on my "problem diagnosis"...

Thanks as always; happy father's day!

Shamish
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Old 06-23-2007, 10:14 AM   #2 (permalink)
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Re: How to replace "clutch pedal position sensor/switch"

Don't know if you have found your answer already as I am just reading this post.
There is a plastic cover that snaps off. After that, the switch assy lifts off of the pushrod. It could be that your switch is not bad, but just not sliding properly on the shaft and is stuck in the 'out' position.
It is a pain to actually see what is going up there, but I have found that once you unsnap that cover the assy (which has a spring and is spring loaded) just lifts off the pushrod.
Good luck. [img]/ubbthreads/images/graemlins/smile.gif[/img]
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Old 06-23-2007, 11:22 AM   #3 (permalink)
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Re: How to replace "clutch pedal position sensor/switch"

I have replaced a couple of them on some trucks. You just have to be good at yoga [img]/ubbthreads/images/graemlins/biggrin.gif[/img]. It really is all about feel. Unsnap the white cover and slide off the switch. Just remember to load the spring in its original position when you put the new one on...that aint very hard. HAVE FUN!! [img]/ubbthreads/images/graemlins/biggrin.gif[/img] [img]/ubbthreads/images/graemlins/smokin.gif[/img] [img]/ubbthreads/images/graemlins/smokin.gif[/img]
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Old 06-25-2007, 09:39 PM   #4 (permalink)
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Re: How to replace "clutch pedal position sensor/switch"

I had this switch go bad on mine. The springs inside went bad and the switch wouldn't return. No cruise, and no APCM were my symptoms. I had a dealer do it. Later my clutch hydraulic system went bad and I pulled that switch myself. I was then kicking myself for having the dealer do something so simple. The hardest part is getting the four tabs to release all the same time. Yoga does help.
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Old 06-26-2007, 06:12 PM   #5 (permalink)
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Re: How to replace "clutch pedal position sensor/switch"

Try this first, though - I had the same problem with mine, and found out that the switch was sticking on the pushrod - I hit it with some WD40 and it has worked fine ever since. Low tech, but cheaper than a new switch.

CB
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Old 06-26-2007, 07:14 PM   #6 (permalink)
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Re: How to replace "clutch pedal position sensor/switch"

This switch is two switches in one. It detects both fully depressed and fully up positions of the clutch pedal. It is supposed to slide freely on the clutch pushrod, and spring forces normally keep it against the firewall.

It's a clamshell with four plastic latch tabs. You'll want a pick or a sharp miniature flat head screwdriver. I hosed mine down with spray lubricant to no avail, because one of the coil springs had broken. There are a pair of them, one on each side of the pushrod. With only one in service, it got in a bind and wouldn't register the "fully up" position.

My switch failure caused my cruise control to cease working.
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Old 07-01-2007, 02:26 PM   #7 (permalink)
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Re: How to replace "clutch pedal position sensor/switch"

Folks,

Thanks for the great advice!

Before waiting to hear back from the group, I went ahead and called a dealer, and they offered the same guidance that you all did. While it definately took some contorting on my part, I was able to swap the swtiches out in a few minutes.

I noticed that the springs in my switch were corroded (and that they had broken and "bunched up". This prevented the switch from returning to the "clutch released" position, which resulted in the problems that some of you described. I could not figure out how the springs corroded (I could not see any evidence of water getting into it, or through the firewall), but I now know what to do the next time this happens.

Also, thank goodness that the switch failed in the "clutch pedal down" position - it'd be a real bummer if it failed in the other position, since we could not start the truck!

Thanks again for the great advice...I might add one of these to my emergency kit, but we'll have to think about that for a while.

Shamish
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