Clutch Master Cylinder & Reservoir: Installation
WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Install the new push rod in the clutch master cylinder.
- Support the hydraulic components so that the reservoir is above the master cylinder.
- Purge the air from the clutch master cylinder assembly. Install the reservoir cap, and cap the port in the master cylinder after purging the system of air.
- Fill the reservoir with brake fluid. Allow the fluid to flow through the master cylinder and run out into the container. DO NOT let the reservoir run dry. Repeat this process, refilling the reservoir 2 to 3 times, to ensure that all air purged from the assembly. Install the reservoir cap, and cap the port in the master cylinder after purging the system of air.
- Remove the cap from the opening in the hydraulic tube. Position the new O-ring seal on the end of the hydraulic tube. Coat the O-ring seal with brake fluid.
- Remove the cap from the port in the clutch master cylinder. Connect and secure the hydraulic tube to the clutch master cylinder.
- Connect the hydraulic tube to the clutch master cylinder.
- Install the new roll pin.
- Bench bleed the clutch hydraulic system. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
- Position the clutch hydraulic system in the vehicle.
- Verify that the reservoir-to-master cylinder tube routing is as shown so as not to trap air in the clutch hydraulic system. Correct the routing as necessary.
- The routing for vacuum boost brakes and hydraboost brakes differ. Also, the reservoir location for 6.0L vehicles differ. Make sure the tube is routed correctly during installation.
Courtesy of FORD MOTOR CO.
Courtesy of FORD MOTOR CO.
- Attach the clutch hydraulic reservoir.
- Install the clutch master cylinder.
- Compress and twist the clutch master cylinder counterclockwise 45 degrees to lock it to the clutch pedal and support bracket.
- Seat the clutch master cylinder rubber seal to the bulkhead.
- Route the clutch master cylinder-to-slave cylinder hydraulic tube under the brake booster reservoir.
- Connect the power distribution box to the bracket.
- Install the clutch pedal position switch on the clutch master cylinder, push rod, and secure it with the switch cover.
- Install the new push rod bushing.
- Connect the clutch master cylinder push rod to the clutch pedal.
- Raise and support the vehicle.
- Correctly route the hydraulic tube and slave cylinder to the transmission.
- Install the slave cylinder.
- Compress and twist the slave cylinder to lock it onto the transmission.
- Connect the clutch hydraulic tube to the floor pan clip.
- Lower the vehicle.
- Connect the clutch hydraulic tube to the dash clip.
- Press the clutch pedal to seat the push rod in the clutch master cylinder.
- Test the system for normal operation.
CAUTION:
The push rod is not removable after installing it in the clutch master cylinder.
CAUTION:
Place a suitable container under the clutch master cylinder.
CAUTION:
DO NOT
let the reservoir run dry.
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.
WARNING:
The clutch pedal is under spring tension.