Clutch Master Cylinder: Service and Repair

Clutch Master Cylinder and Reservoir





Clutch Hydraulic System









Removal

NOTE: Remove the entire clutch hydraulic system from the vehicle as an assembly when installing a new clutch master cylinder assembly. The clutch master cylinder is only serviced in the assembly.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. NOTE: The clutch control system has a heat shield that covers most of the tube and clutch slave cylinder. To unlock the slave cylinder, slide the heat shield back and off of the slave cylinder.

Unlock and remove the clutch slave cylinder from the transmission.

- Slide the heat shield back and rotate counterclockwise 45 degrees while pushing inward.





3. Disconnect the clutch hydraulic tube from the floor pan clip and the dash clip. Position the clutch slave cylinder and hydraulic tube forward below the left engine bank.

4. NOTE: The clutch pedal is under spring tension.

Working inside the vehicle, unlock the push rod retaining clips and separate the clutch master cylinder push rod from the clutch pedal.





5. Remove and discard the clutch master cylinder push rod bushing.

6. Remove the switch cover and the Clutch Pedal Position (CPP) switch from the clutch master cylinder push rod.





7. Remove the bolt and the clutch master cylinder reservoir.





8. Remove the nuts and position the brake master cylinder aside.





9. Unlock and remove the clutch master cylinder from the clutch pedal and support bracket.
- Push inward and twist the clutch master cylinder clockwise 45 degrees to unlock it from the clutch pedal and support bracket.

10. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

Remove the clutch hydraulic system from the vehicle.

Installation

1. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

NOTICE: The push rod is not removable after installing it in the clutch master cylinder.

Install the new push rod in the clutch master cylinder and position the clutch hydraulic system in the vehicle.

2. Lock the clutch master cylinder to the clutch pedal and support bracket.
- Push inward and twist the clutch master cylinder counterclockwise 45 degrees to lock it to the clutch pedal and support bracket.

- Seat the clutch master cylinder rubber seal to the bulkhead after locking the clutch master cylinder in the clutch pedal and support bracket.

3. Install the clutch master cylinder reservoir and bolt.
- Tighten to 12 Nm (106 lb-In)





4. Install the brake master cylinder and install the nuts.
- Tighten to 24 Nm (18 lb-ft)





5. NOTICE: When installed correctly, the flat side of the CPP switch must face the tab protruding from the clutch master cylinder and the switch wiring connector must be in the 12 o'clock position. Incorrect installation will damage the CPP switch and cause insufficient clutch pedal travel.

Install the CPP switch on the clutch master cylinder push rod and install the cover.





6. Install a new clutch master cylinder push rod bushing.

7. NOTE: The clutch pedal is under spring tension.

Using a new master cylinder push rod bushing lock the clutch master cylinder push rod to the clutch pedal.





8. Connect the clutch hydraulic tube to the floor pan clip and the dash clip.

9. NOTE: The clutch control system has a heat shield that covers most of the tube and clutch slave cylinder. Make sure to slide the heat shield forward and over the slave cylinder until it contacts the transmission case.

Install the clutch slave cylinder.

- Push in and rotate clockwise 45 degrees to the lock position.

- Slide the heat shield over the slave cylinder.





10. Test the system for normal operation.