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

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.

Disconnect the clutch hydraulic tube from the dash clip. See Fig 1 . Raise and support the vehicle. Unlock and remove the slave cylinder from the transmission by compressing and twisting the slave cylinder to unlock it from the transmission. See Figure .
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.

NOTE: The clutch pedal is under spring tension.

Lower the vehicle. Unlock the push rod bushing retaining clips and separate the clutch master cylinder push rod from the clutch pedal. See Fig 2 . 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. See Fig 2 . Separate the power distribution box from the bracket to gain access to the clutch master cylinder. See Fig 3 .
Unlock and remove the clutch master cylinder from the clutch pedal and support bracket by compressing and twisting the clutch master cylinder clockwise 45 degrees to unlock it from the clutch pedal and support bracket. See Fig 4 .
Remove the clutch hydraulic reservoir from the wiring tray and separate the clutch hydraulic tube from the brake master cylinder assembly. See Figure . Position the clutch hydraulic reservoir aside. Remove the clutch hydraulic system from the vehicle.
Clean the clutch hydraulic system components to prevent contaminants from entering the hydraulic system. Place a suitable container under the clutch master cylinder.
Using a 3/32" punch and a hammer, drive out the roll pin, and discard it. See Fig 5 . 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.

Fig 1: Locating Dash Clip (F250-F550)

Courtesy of FORD MOTOR CO.

Fig 2: Locating Clutch Pedal Position Switch (F250-F550)

Courtesy of FORD MOTOR CO.

Fig 3: Locating Power Distribution Box (F250-F550)

Courtesy of FORD MOTOR CO.

Fig 4: Removing & Installing Clutch Master Cylinder (F250-F550)

Courtesy of FORD MOTOR CO.

Fig 5: Removing & Installing Hydraulic Line From Clutch Master Cylinder (F250-F550)

Courtesy of FORD MOTOR CO.