Removal and 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.
- Disconnect the clutch hydraulic tube from the dash clip.
- Raise and support the vehicle.
- Unlock and remove the slave cylinder (7A564) from the transmission.
- Compress and twist the slave cylinder to unlock it from the transmission.
- 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.
- Lower the vehicle.
- 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 (7526).
- Remove the switch cover, and remove the clutch pedal position switch (7C534) from the clutch master cylinder push rod.
- Separate the power distribution box from the bracket to gain access to the clutch master cylinder.
- 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.
- Remove the nuts.
- Remove the nuts and the clutch pedal and support bracket.
- 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.
- Correctly position the clutch pedal position switch when installing it on the clutch master cylinder push rod.
WARNING:
The clutch pedal is under spring tension.
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.