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. Working under the instrument panel, remove the clutch master cylinder nut.





2. Using a suitable suction tool, remove the brake fluid to just below the clutch reservoir hose.





3. Remove the battery tray. For additional information, refer to Battery.

4. Remove the PCM.

1. Disconnect the electrical connectors.

2. Remove the 2 PCM bolts.





5. Remove 3 PCM bracket nuts and the PCM bracket.





6. Disconnect the clutch master cylinder-to-clutch hydraulic tube.





7. Disconnect the clutch master cylinder reservoir hose.





8. Remove the clutch master cylinder nut.





9. Remove the clutch master cylinder assembly.

Installation

1. Install the clutch master cylinder assembly.

2. Install the clutch master cylinder nut.
- Tighten to 21 Nm (15 lb-ft).





3. Working under the instrument panel, install the clutch master cylinder nut.
- Tighten to 21 Nm (15 lb-ft).





4. Connect the clutch master cylinder reservoir hose.





5. Connect the clutch master cylinder-to-clutch hydraulic tube.
- Tighten the clutch hydraulic tube nut to 17 Nm (150 lb-in).





6. Install the PCM bracket and 3 PCM bracket nuts.
- Tighten to 10 Nm (89 lb-in).





7. Install the PCM.

1. Install the 2 PCM bolts.
- Tighten to 10 Nm (89 lb-in).

2. Connect the electrical connectors.





8. Install the battery tray. For additional information, refer to Battery.

9. Bleed the clutch hydraulic system. For additional information, refer to Manual Transmission/Transaxle &/or Clutch, M/T.