Removal & Installation - Explorer

WARNING: This page is about a different car, the 2002 Ford Ranger, 2002 Ford Explorer Sport Trac, 2002 Ford Explorer Sport, and 2002 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.

CAUTION: Brake fluid is harmful to painted or plastic surfaces. If the brake fluid is spilled onto a painted or plastic surface, wash it immediately with water.

Partially drain the brake and clutch reservoir. Drain to just below the clutch reservoir nipple.
Remove the hose at the brake and clutch reservoir.
Remove the clip and washer from the clutch pedal pin. See Fig 1.

Fig 1: Locating Clip & Washer At Clutch Pedal Pin
Courtesy of FORD MOTOR CO.
Remove the two bolts, then disconnect the clutch master cylinder from the clutch pedal. See Fig 2.

Fig 2: Locating Clutch Master Cylinder Bolts With Torque Specifications
Courtesy of FORD MOTOR CO.
Pull the clutch master cylinder forward until the line clip is accessible. See Fig 3. Remove the clip and disconnect the line.

Fig 3: Locating Clutch Master Cylinder Line Clip
Courtesy of FORD MOTOR CO.
Disconnect the clutch master cylinder rod from the clutch pedal arm. See Fig 4. Remove the clutch master cylinder from the vehicle.

Fig 4: Locating Clutch Master Cylinder Rod At Clutch Pedal Arm
Courtesy of FORD MOTOR CO.
Remove the reservoir line from the clutch master cylinder.
To install, reverse the removal procedure.
- Install new hose clamps on the reservoir line.
- Refill the brake master cylinder with the specified fluid.
- Bleed the clutch hydraulic system.