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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 670 (Clutch Controls System -- F250-F550 Super Duty) >> Removal And Installation >> Clutch Master Cylinder and Reservoir >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 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.
  1. Disconnect the clutch hydraulic tube from the dash clip.
    Fig 1: Disconnecting Clutch Hydraulic Tube From Dash Clip
    G02776388Courtesy of FORD MOTOR CO.
  2. With the vehicle in NEUTRAL, position it on a hoist. Refer to JACKING & LIFTING .
  3. Unlock and remove the clutch slave cylinder from the transmission.
    • Compress and twist the clutch slave cylinder counterclockwise to unlock it from the transmission.
      Fig 2: Removing Clutch Slave Cylinder From Transmission
      G02776389Courtesy 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: Identifying Retaining Clips
    G02776390Courtesy of FORD MOTOR CO.
  6. Unlock the push rod retaining clips and separate the clutch master cylinder push rod from the clutch pedal.
  7. Remove and discard the clutch master cylinder push rod bushing.
  8. Remove the switch cover and the clutch pedal position switch from the clutch master cylinder push rod.
    Fig 4: Removing Clutch Pedal Position Switch From Clutch Master Cylinder Push Rod
    G02776391Courtesy 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
    G02776392Courtesy of FORD MOTOR CO.
  10. 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.
    11. 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.
  11. Remove the clutch hydraulic system from the vehicle.
    12. 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.
  12. To install, reverse the removal procedure.
      CAUTION: The push rod is not removable after installing it in the clutch master cylinder.
    • Install the new push rod in the clutch master cylinder.
    • Install a new push rod bushing.
  13. Press the clutch pedal to seat the push rod in the clutch master cylinder.
  14. Test the system for normal operation.
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