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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 Pedal >> 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.
  1. Disconnect the clutch hydraulic tube from the dash clip.
    Fig 1: Disconnecting Clutch Hydraulic Tube From Dash Clip
    G02776379Courtesy of FORD MOTOR CO.
  2. Raise and support the vehicle. Refer to JACKING & LIFTING .
  3. Unlock and remove the slave cylinder (7A564) from the transmission.
    • Compress and twist the slave cylinder to unlock it from the transmission.
      Fig 2: Removing Slave Cylinder From Transmission
      G02776380Courtesy of FORD MOTOR CO.
  4. Disconnect the clutch hydraulic tube from the floor pan clip. Position the 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 (7B633) by reducing tension on the hydraulic tube.
  5. Lower the vehicle.
    6. WARNING: The clutch pedal is under spring tension.
    Fig 3: Retaining Clips
    G02776381Courtesy 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 (7526).
  8. Remove the switch cover, and remove the clutch pedal position switch (7C534) from the clutch master cylinder push rod.
    Fig 4: Removing Clutch Pedal Position Switch
    G02776382Courtesy 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
    G02776383Courtesy 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.
      Fig 6: Removing Clutch Master Cylinder From Clutch Pedal
      G02776384Courtesy of FORD MOTOR CO.
  11. Remove the nuts.
    Fig 7: Removing Nuts
    G02776385Courtesy of FORD MOTOR CO.
  12. Remove the nuts and the clutch pedal and support bracket.
    Fig 8: Removing Nuts And Clutch Pedal And Support Bracket
    G02776386Courtesy of FORD MOTOR CO.
  13. To install, reverse the removal procedure noting the following:
    • Seat the clutch master cylinder rubber seal to the bulkhead after locking the clutch master cylinder in the clutch pedal and support bracket.
    • Route the clutch master cylinder-to-slave cylinder hydraulic tube under the brake booster after installing the clutch master cylinder.
    14. 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.
    Fig 9: Installing Clutch Pedal Position Switch
    G02776387Courtesy of FORD MOTOR CO.
  14. Correctly position the clutch pedal position switch when installing it on the clutch master cylinder push rod.
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