Clutch Master Cylinder: Installation

Attach the clutch master cylinder to the clutch pedal assembly.
- Attach the actuating rod to the pedal arm. Install the clutch master cylinder bolts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 1: Locating Clutch Master Cylinder Bolts
  Courtesy of FORD MOTOR CO.
Position the clutch pedal assembly in the vehicle.

CAUTION: Make sure the brake pedal actuating rod retaining pin is locked in position. When correctly installed, the locking tab on the side of the retaining pin will be visible as it extends through the actuating rod and the brake pedal.

CAUTION: Push and pull the retaining pin to make sure it is correctly installed.

Fig 2: Installing Brake Pedal Actuating Rod Retaining Pin

Courtesy of FORD MOTOR CO.

Install the brake pedal actuating rod retaining pin.
Install the clutch pedal assembly nuts.
- Tighten to 23 Nm (17 lb-ft).
  
  Fig 3: Identifying Clutch Pedal Assembly Nuts
  Courtesy of FORD MOTOR CO.
Attach the lower hydraulic line to the front bulkhead and install the clip.

Fig 4: Locating Clip
Courtesy of FORD MOTOR CO.

NOTE: The clutch position switch (red) is not adjustable.

Pull out the starter safety switch, speed control deactivation switch and brake lamp switch plungers until they are fully extended.
- Measure the plunger length.
  - Speed control deactivation switch (green) XX mm = 24 mm.
  - Brake lamp switch (grey) XX mm = 21 mm.
  - Starter safety switch (black) XX mm = 26 mm.
    
    Fig 5: Measuring Plunger Length
    Courtesy of FORD MOTOR CO.

CAUTION: When installing the switches, the brake lamp switch is rotated counterclockwise and the remaining switches are rotated clockwise. Failure to follow this instruction will result in the switch plungers binding inside the switch.

CAUTION: Make sure the switches are correctly installed.

NOTE: The speed control deactivation switch and the stop lamp switch are automatically adjusted during installation.

NOTE: A slight ratcheting noise and feel during installation of the speed control deactivation switch and the brake lamp switch is normal.

Install the switches to the pedal assembly.
1. Speed control deactivation switch (green).
2. Brake lamp switch (grey).
3. Clutch position switch (red).
4. Starter safety switch (black).
  
  Fig 6: Installing Switches To Pedal Assembly
  Courtesy of FORD MOTOR CO.

NOTE: The colors of the electrical connectors and the switches are identical.

Connect the electrical connectors to the pedal assembly switches.

NOTE: A slight ratcheting noise and feel during switch adjustment is normal.

Adjust the starter safety switch (black) by pressing and then releasing the clutch pedal.

NOTE: Install new O-ring seals.

Fig 7: Locating Slave Cylinder Fluid Supply Lines

Courtesy of FORD MOTOR CO.

Connect the clutch master cylinder and slave cylinder fluid supply lines to the clutch master cylinder, then insert the clips.
Connect the hood release cable and the data link connector to the instrument panel lower panel.

Fig 8: Locating Data Link Connector
Courtesy of FORD MOTOR CO.
Install the instrument panel lower panel trim to the instrument panel.
1. Secure the fastener.
2. Install the screws.
  
  Fig 9: Locating Fastener And Screws
  Courtesy of FORD MOTOR CO.
Attach the central junction box (CJB) to the mounting bracket.
1. Install the retaining bolt.
2. Attach the clip.
  
  Fig 10: Locating Central Junction Box (CJB) Clip
  Courtesy of FORD MOTOR CO.
Fill the brake fluid reservoir to the MAX mark with the specified fluid.
Bleed the hydraulic clutch system. For additional information, refer to MANUAL TRANSAXLE-TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
Connect the battery ground cable. For additional information, refer to BATTERY MOUNTING AND CABLES .