Five problems related to clutch have been reported for the 1997 Ford F-150. The most recently reported issues are listed below.
The clutch seal shrunk when the weather was cold which caused fluid to run out.
The slave cylinder has broke twice now, and I have a friend with a 1993 f150 and it does the same thing when ever the temperature is below 0 degrees f. This usually occurs on the initial start of the day. After the cylinder breaks, the clutch makes a whine when depressed. This also effects the ability to shift. The crack in the sheet metal on the drivers door is approximately 1" in length and this vehicle has never been wrecked or even bumped since I have had it since new.
Wanted to slow down on snow covered road for stopped traffic ahead/pushed in clutch/attempted to downshift from 4th gear/found shift lever to be locked up/clutch would not disengage/found it near impossible to brake vehicle to a stop/was forced to drive vehicle off road to avoid hitting stopped vehicle in rear. Stopped vehicle by shutting off engine. Found the clutch cylinder out of fluid. Refilled and clutch action seemed ok. Could not find any noticeable leaks. Called dealership. Talked to service rep. Rep felt it may off been low on fluid due to cluch wear. Drove about 35 miles and again when I attemped to downshift to slow down for stop light /no clutch operation. No clutch fluid. Only way one can shift to neutral is to shut engine off. Very dangerous . Discovered when I took vehicle in for repair that a o-ring in clutch slave cylinder leaked. Ford tech said this a common problem especially if it is very cold temperature outside. Funny Ford had a similar clutch problem with their 1987 f150 trucks except it was due to a weak firewall mounting for clutch oil resorivor. Again clutch would not disengage properly and Ford had a factory modification to fix.
Clutch slave assembly can start leaking at any time, rendering clutch useless, causing stalling, and lunging at a stop. Ford has redesigned the part, meaning the original has a flaw. (tech bulletin # bc2301970501,) but safety warrants a recall.
Slave cylinder failed.