LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2005 >> Escape Hybrid, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 806 (Clutch Control System - F250-F550) >> Removal And Installation >> Clutch Master Cylinder and Reservoir >> Removal And Installation

Removal And Installation

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Remove the entire clutch hydraulic system from the vehicle as an assembly when installing a new clutch master cylinder assembly. The clutch master cylinder is only serviced in the assembly.
  1. Disconnect the clutch hydraulic tube from the dash clip.
    2. Fig 1: Locating Dash Clip
    GF0007159Courtesy of FORD MOTOR CO.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
    3. NOTE: The clutch control system has a heat shield that covers most of the tube and clutch slave cylinder. To unlock the slave cylinder, slide the heat shield back and off of the slave cylinder. Slide the heat shield over the tube.
  3. Unlock and remove the clutch slave cylinder from the transmission.
    • Compress and twist the clutch slave cylinder counterclockwise to unlock it from the transmission.
    4. Fig 2: Locating Slave Cylinder
    G03923327Courtesy of FORD MOTOR CO.
  4. Disconnect the clutch hydraulic tube from the floor pan clip. Position the clutch 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.
    5. NOTE: The clutch pedal is under spring tension.
  5. Working inside the vehicle, unlock the push rod retaining clips and separate the clutch master cylinder push rod from the clutch pedal.
  6. Remove and discard the clutch master cylinder push rod bushing.
    7. Fig 3: Identifying Push Rod Bushing
    GF0007162Courtesy of FORD MOTOR CO.
  7. Remove the switch cover and the clutch pedal position (CPP) switch from the clutch master cylinder push rod.
    8. Fig 4: Locating Clutch Pedal Position (CPP) Switch
    GF0007163Courtesy of FORD MOTOR CO.
  8. Separate the power distribution box from the bracket to gain access to the clutch master cylinder.
    9. Fig 5: Locating Power Distribution Box
    GF0007160Courtesy of FORD MOTOR CO.
  9. 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.
    10. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
    CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled on a painted or plastic surface, wash the affected area immediately with cold water.
  10. Remove the clutch hydraulic system from the vehicle.
    11. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
    CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled on a painted or plastic surface, wash the affected area immediately with cold water.
    CAUTION: When installed correctly, the flat side of the clutch pedal position (CPP) 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 CPP switch and cause insufficient clutch pedal travel.
  11. To install, reverse the removal procedure.
      CAUTION: The push rod is not removable after installing it in the clutch master cylinder.
    • Install the new push rod in the clutch master cylinder.
    • Install a new push rod bushing.
    • Make sure to slide the heat shield forward and over the slave cylinder until it contacts the transmission case.
  12. Press the clutch pedal to seat the push rod in the clutch master cylinder.
  13. Test the system for normal operation.
scientia non olet · About LEMON Manuals