Clutch Master Cylinder & Reservoir: Removal

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.

CAUTION: Remove the entire clutch hydraulic system from the vehicle as an assembly when installing a new clutch master cylinder assembly.

Disconnect the clutch hydraulic tube from the dash clip.

Fig 1: Disconnecting Clutch Hydraulic Tube From Dash Clip
Courtesy of FORD MOTOR CO.
Raise and support the vehicle.
Unlock and remove the slave cylinder from the transmission.
- Compress and twist the slave cylinder to unlock it from the transmission.
Fig 2: Unlocking Slave Cylinder
Courtesy of FORD MOTOR CO.
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 by reducing tension on the hydraulic tube.
Lower the vehicle.

WARNING: The clutch pedal is under spring tension.

Fig 3: Identifying Push Rod Bushing Retaining Clips

Courtesy of FORD MOTOR CO.

Unlock the push rod bushing retaining clips and separate the clutch master cylinder push rod from the clutch pedal.
Remove and discard the push rod bushing.
Remove the switch cover, and remove the clutch pedal position switch from the clutch master cylinder push rod.

Fig 4: Removing Switch Cover
Courtesy of FORD MOTOR CO.
Separate the power distribution box from the bracket to gain access to the clutch master cylinder.

Fig 5: Removing Power Distribution Box
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
Remove the clutch hydraulic reservoir. Position the clutch hydraulic reservoir aside.
- For 5.4L, 6.8L and 7.3L vehicles, remove the reservoir from the wiring tray and separate the clutch hydraulic tube from the brake master cylinder.
- For 6.0L vehicles, remove the reservoir from the power steering reservoir.
Fig 7: Removing Clutch Hydraulic Reservoir (With Vacuum Power Booster)
Courtesy of FORD MOTOR CO.

Fig 8: Removing Clutch Hydraulic Reservoir (With Hydraulic Power Booster)
Courtesy of FORD MOTOR CO.

Fig 9: Removing Clutch Hydraulic Reservoir (With 6.0L Diesel)
Courtesy of FORD MOTOR CO.

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.

Fig 10: Removing Clutch Hydraulic System

Courtesy of FORD MOTOR CO.

Remove the clutch hydraulic system from the vehicle.
Clean the clutch hydraulic system components to prevent contaminants from entering the hydraulic system.

CAUTION: Place a suitable container under the clutch master cylinder.

Fig 11: Disconnecting Hydraulic Tube From Clutch Master Cylinder

Courtesy of FORD MOTOR CO.

Disconnect the hydraulic tube from the clutch master cylinder.
1. Using a 3/32-inch punch and a hammer, drive out the roll pin, and discard it.
2. Disconnect the hydraulic tube from the clutch master cylinder.

NOTE: Sometimes the O-ring seal will remain inside the clutch master cylinder.

Remove the O-ring seal from the end of the hydraulic tube, and discard it. Cap the open end of the hydraulic tube.