Clutch Master Cylinder: Service and Repair

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 serious personal injury.

WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury.

WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment.

1. Remove the brake fluid reservoir cap.

2. Drain the brake fluid into a suitable container until the brake fluid level reaches the MIN mark.

3. Disconnect the clutch master cylinder tubes.

4. Disconnect the clutch pedal position switch, starter inhibitor switch electrical connectors and remove the 3 clutch pedal assembly nuts.

5. Remove the clutch pedal/ master cylinder assembly.

Installation

1. Install the clutch pedal/ master cylinder assembly

2. Install the 3 clutch pedal assembly nuts, connect the starter inhibitor switch and clutch pedal position switch electrical connectors.
- Tighten to 25 Nm (18 lb-ft).

3. Connect the clutch master cylinder tubes.

4. Bleed the clutch hydraulic system. For additional information, refer to Manual Transaxle/Transmission and Clutch - General Information Service and Repair.