Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

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 personal injury.

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

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

CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with clean specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system.

NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment.

Using a suitable suction tool, remove the brake fluid to just below the clutch reservoir hose.

Fig 1: Locating Brake Fluid To Clutch Reservoir Hose
Disconnect the clutch slave cylinder-to-clutch master cylinder line.

Fig 2: Locating Clutch Slave Cylinder-To-Clutch Master Cylinder Line
Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder.
- To install, tighten to 19 Nm (14 lb-ft).
  
  Fig 3: Identifying Clutch Slave Cylinder Bolts
To install, reverse the removal procedure.
- Apply a small amount of grease on the end of the slave cylinder push rod.
- Bleed the air from the system. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .