Clutch Master Cylinder: Removal

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 personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water. If spilled on a plastic surface, wipe up immediately.

Disconnect the battery ground cable. For additional information, refer to BATTERY MOUNTING AND CABLES .

CAUTION: The brake fluid reservoir cap must not become contaminated.

Using a suitable tool, remove brake fluid from the brake fluid reservoir until the brake fluid level is at the MIN mark.
- Install the brake fluid reservoir cap.
  
  Fig 1: Removing Brake Fluid From Brake Fluid Reservoir
  Courtesy of FORD MOTOR CO.
Detach the central junction box (CJB) from the mounting bracket.
1. Remove the CJB bolt.
2. Release the clip.
  
  Fig 2: Locating Clip
  Courtesy of FORD MOTOR CO.

NOTE: Cap the upper hydraulic and lower hydraulic supply lines to prevent fluid loss.

Fig 3: Locating Clutch Hydraulic Lines

Courtesy of FORD MOTOR CO.

Remove the clips, then disconnect the clutch hydraulic lines.
Remove the instrument panel lower panel from the instrument panel.
1. Remove the screws.
2. Release the fastener.
  
  Fig 4: Locating Fastener And Screws
  Courtesy of FORD MOTOR CO.
Remove the instrument panel lower panel.
- Detach the data link connector.
- Disconnect the hood release cable.
  
  Fig 5: Locating Data Link Connector
  Courtesy of FORD MOTOR CO.
Remove the clip, then disconnect the upper hydraulic line from the front bulkhead.

Fig 6: Locating Clip
Courtesy of FORD MOTOR CO.
Depress the locking tang and remove the brake pedal actuating rod retaining pin.

Fig 7: Removing Brake Pedal Actuating Rod Retaining Pin
Courtesy of FORD MOTOR CO.
Disconnect the starter safety switch, clutch position switch, speed control deactivation switch and brake lamp switch electrical connectors from the pedal assembly.
Remove the switches from the pedal assembly.
1. Speed control deactivation switch (green).
2. Stop lamp switch (grey).
3. Clutch position switch (red).
4. Starter safety switch (black).
  
  Fig 8: Removing Stop Lamp Switch Switches From Pedal Assembly
  Courtesy of FORD MOTOR CO.

NOTE: The complete clutch pedal assembly and the clutch master cylinder must be removed to gain access to the clutch master cylinder bolts.

Fig 9: Locating Clutch Pedal Assembly Nuts

Courtesy of FORD MOTOR CO.

Remove the clutch pedal assembly nuts and the pedal assembly.
Separate the clutch master cylinder from the clutch pedal.
- Mount the pedal assembly in a suitable vise. Remove the clutch master cylinder bolts. Detach the clutch master cylinder from the pedal assembly and slide the actuating rod from the pedal arm.
  
  Fig 10: Locating Clutch Master Cylinder Bolts
  Courtesy of FORD MOTOR CO.