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.
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.
- Disconnect the clutch hydraulic tube from the dash clip.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
- Unlock and remove the clutch slave cylinder from the transmission.
- Compress and twist the clutch slave cylinder counterclockwise to unlock it from the transmission.
- 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.
- Unlock the push rod retaining clips and separate the clutch master cylinder push rod from the clutch pedal.
- Remove and discard the clutch master cylinder push rod bushing.
- Remove the switch cover and the clutch pedal position switch from the clutch master cylinder push rod.
- Separate the power distribution box from the bracket to gain access to the clutch master cylinder.
- Unlock and remove the clutch master cylinder from the clutch pedal and support bracket.
- Compress and twist the clutch master cylinder clockwise 45 degrees to unlock it from the clutch pedal and support bracket.
- Remove the clutch hydraulic system from the vehicle.
- To install, reverse the removal procedure.
- Install the new push rod in the clutch master cylinder.
- Install a new push rod bushing.
- 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.
CAUTION: The push rod is not removable after installing it in the clutch master cylinder. - Press the clutch pedal to seat the push rod in the clutch master cylinder.
- Test the system for normal operation.
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 of the slave cylinder. Slide the heat shield over the tube.
WARNING:
The clutch pedal is under spring tension.
CAUTION:
Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately.
CAUTION:
Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately.
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.