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Removal and Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the clutch hydraulic tube from the dash clip.
    Fig 1: Disconnecting Clutch Hydraulic Tube From Dash Clip
    G03923351Courtesy of FORD MOTOR CO.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  3. 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
      G03923327Courtesy of FORD MOTOR CO.
  4. 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.
  5. Lower the vehicle.
    6. WARNING: The clutch pedal is under spring tension.
    Fig 3: Unlocking Push Rod Bushing Retaining Clips
    G03923353Courtesy of FORD MOTOR CO.
  6. Unlock the push rod bushing retaining clips and separate the clutch master cylinder push rod from the clutch pedal.
  7. Remove and discard the push rod bushing.
  8. Remove the switch cover and the clutch pedal position switch from the clutch master cylinder push rod.
    Fig 4: Removing Switch Cover And Clutch Pedal Position Switch From Clutch Master Cylinder Push Rod
    G03923354Courtesy of FORD MOTOR CO.
  9. Separate the power distribution box from the bracket to gain access to the clutch master cylinder.
    Fig 5: Separating Power Distribution Box From Bracket
    G03923355Courtesy of FORD MOTOR CO.
  10. Remove the clutch master cylinder from the clutch pedal and support bracket, then remove the two 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.
    Fig 6: Removing/Installing Clutch Pedal Support Bracket Nuts
    G03923356Courtesy of FORD MOTOR CO.
  11. Remove the inner clutch pedal and support bracket nuts and the clutch pedal and support bracket.
    Fig 7: Removing/Installing Inner Clutch Pedal And Support Bracket Nuts
    G03923357Courtesy of FORD MOTOR CO.
    12. 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.
  12. 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.
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