Removal and Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the clutch hydraulic tube from the dash clip.

Fig 1: Locating Dash Clip
Courtesy of FORD MOTOR CO.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .

NOTE: The 5.4L and 6.8L 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 the slave cylinder. Slide the heat shield over the tube.

Unlock and remove the slave cylinder from the transmission.
- Compress and twist the clutch slave cylinder counterclockwise to unlock it from the transmission.
  
  Fig 2: Locating Slave Cylinder
  Courtesy of FORD MOTOR CO.
Disconnect the clutch hydraulic tube from the floor pan clip. Position the clutch slave cylinder and hydraulic tube forward below the left engine bank. This will make it easier to unlock the clutch master cylinder from the clutch pedal and support bracket by reducing tension on the hydraulic tube.
Lower the vehicle.

WARNING: The clutch pedal is under spring tension.

Fig 3: Locating Push Rod Bushing

Courtesy of FORD MOTOR CO.

Unlock the push rod bushing retaining clips and separate the clutch master cylinder push rod from the clutch pedal.
Remove and discard the push rod bushing.
Remove the switch cover and the clutch pedal position switch from the clutch master cylinder push rod.

Fig 4: Locating Clutch Pedal Position Switch
Courtesy of FORD MOTOR CO.
Separate the power distribution box from the bracket to gain access to the clutch master cylinder.

Fig 5: Locating Power Distribution Box
Courtesy of FORD MOTOR CO.
Remove the clutch master cylinder from the clutch pedal and support bracket, then remove the 2 outer clutch pedal support bracket nuts.
1. Compress and twist the clutch master cylinder clockwise 45 degrees to unlock it from the clutch pedal and support bracket.
2. Remove the nuts.
  - To install, tighten to 25 Nm (18 lb-ft).
    
    Fig 6: Identifying Clutch Master Cylinder
    Courtesy of FORD MOTOR CO.
Remove the inner clutch pedal and support bracket nuts and the clutch pedal and support bracket.
1. To install, tighten to 25 Nm (18 lb-ft).
  
  Fig 7: Locating Inner Clutch Pedal Support Bracket Nuts
  Courtesy of FORD MOTOR CO.

CAUTION: When installed correctly, the flat side of the clutch pedal position 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 clutch pedal position switch and cause insufficient clutch pedal travel.

To install, reverse the removal procedure noting the following:
- Correctly position the clutch pedal position switch when installing it on the clutch master cylinder push rod.
- Seat the clutch master cylinder rubber seal to the bulkhead after locking the clutch master cylinder in the clutch pedal and support bracket.
- For 5.4L and 6.8L clutch control systems, make sure to slide the heat shield forward and over the slave cylinder until it contacts the transmission case.