LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2004 >> Taurus LX, 3.0 2 >> Repair and Diagnosis >> External Pages >> Different car >> Section 88 (Clutch System - F250-F550 Super Duty) >> Removal & Installation >> Clutch Master Cylinder & Reservoir (F250-F550) >> Installation

Clutch Master Cylinder & Reservoir (F250-F550): Installation

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The push rod is not removable after installing it in the clutch master cylinder.
  1. Install the NEW push rod in the clutch master cylinder. See Fig 1 . Support the hydraulic components so that the reservoir is above the master cylinder. See Fig 2 . Purge the air from the clutch master cylinder assembly.
  2. Fill the reservoir with Ford High Performance DOT 3 Motor Vehicle Brake Fluid (C6AZ-19542-AB). Allow the fluid to flow through the master cylinder and run out into the container. DO NOT let the reservoir run dry.
  3. 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.
  4. 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 High Performance DOT 3 Motor Vehicle Brake Fluid (C6AZ-19542-AB).
  5. Remove the cap from the port in the clutch master cylinder. Connect and secure the hydraulic tube to the clutch master cylinder with a NEW roll pin. See Figure . Bench bleed the clutch hydraulic system. See BLEEDING  .
  6. Position the clutch hydraulic system in the vehicle. Correctly route the clutch hydraulic tube and attach the clutch hydraulic reservoir to the wiring tray. See Figure .
  7. Install the clutch master cylinder by compressing and twisting the clutch master cylinder counterclockwise 45 degrees to lock it to the clutch pedal and support bracket. See Figure .
  8. 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.
    9. NOTE: 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.
  9. Connect the power distribution box to the bracket. See Figure . Install the CPP switch on the clutch master cylinder push rod, and secure it with the switch cover. See Figure . Install the NEW push rod bushing.
    10. NOTE: The clutch pedal is under spring tension.
  10. 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.
  11. Compress and twist the slave cylinder to lock it onto the transmission. See Figure . Connect the clutch hydraulic tube to the floor pan clip. Lower the vehicle.
  12. Connect the clutch hydraulic tube to the dash clip. See Figure . Press the clutch pedal to seat the push rod in the clutch master cylinder. Test the system for normal operation.
Fig 1: Installing New Pushrod (F250-F550)
G00193870Courtesy of FORD MOTOR CO.
Fig 2: Purging Air From Clutch Master Cylinder (F250-F550)
G00193871Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals