I've noticed that my clutch pedal free play will change from time to time. I haven't noticed a correlation with any specific condition, but sometimes it feels normal, and other times there is a good 1-2" of free play.

In either state the clutch works fine. It goes into gear and shifts without an issue.

I can't help but wonder if this is an early sign of the master or slave getting ready to fail, or the pressure plate fingers getting sticky or something.

Anyone else had this happen?

98 2.5 5 speed

 

Check bushing at the top of the pedal arm, and the shaft for play

The pressure plate has more than enough force to push slave back, and pedal would sit lower if "fingers" weren't pushing back enough
There is no return spring on clutch pedal, the pressure plate "fingers" is what pushes pedal back up

You could test masters valve by removing reservoir cap and watching fluid level as someone pushes clutch pedal down.
The valve in the master is one-way, it allows fluid to flow into the master, in case of a leak, but should stop it from flowing back up into reservoir, could be valve is sticking open for a second when you press down on the pedal

But if you notice a change in clutch pedal feel then there is a problem
I assume it's not a change in pedal height

 

It is a change in height, like the master isn't returning all the way. I can lift the pedal a couple inches with my foot when it acts up.

 

Check the "valve" as described above, clutch pedal going in and out should not effect fluid in reservoir at all, 0 movement of fluid

Here is a picture of two brake clutch assemblies: http://www.explorerforum.com/forums/...180-jpg.56494/

One on the left is obviously broken

Picture here of wear before it breaks: DSCN1647.jpg Photo by mikegt777 | Photobucket

So check that, see if pedal pivot is "out of wack" causing the issue, just put hand up under the dash and feel the pivot point while you lift and push on pedal, should be no slop

It could be the master's piston is sticking, but never heard or read about that happening

 

I just noticed that the throwout bearing is squeaking, so I'm 90% sure that it's the culprit.

What is the best clutch for heavy use? I pull a trailer quite a bit and do a lot of city type of driving that is hard on a clutch.

 

LUK is a good brand, they make the Ford clutches as well, but under Motorcraft brand, so not exactly the same but also doesn't cost the same either