OEM 2002 Ford F-350 Super Duty Clutch Master Cylinder

2002 Ford F-350 Super Duty Clutch Master Cylinder Parts Q&A

• Q: How to service and repair the clutch master cylinder and reservoir on 2002 Ford F-350 Super Duty?

  A: The removal of an entire clutch hydraulic system assembly should be performed to install a new clutch master cylinder assembly. Disconnect the clutch hydraulic tube from the dash clip after raising and supporting the vehicle while unlocking the slave cylinder from the transmission through compression and twisting. Position the slave cylinder together with the hydraulic tube below the left engine bank forward to decrease hydraulic tube stress after disconnecting it from the floor pan clip. Lower the vehicle to access the push rod bushing retaining clips while unlocking them for separation of the clutch master cylinder push rod from the clutch pedal. Then discard the push rod bushing. The setup requires personnel to detach the clutch pedal position switch and switch cover from the clutch master cylinder push rod along with disconnecting the power distribution box from its bracket for clutch master cylinder assessment. The clutch master cylinder requires removal when the technician twists it clockwise by 45 degrees while compressing its components. After removing the clutch hydraulic reservoir from the wiring tray they can split the clutch hydraulic tube from the brake master cylinder assembly before placing the reservoir aside. Prepare the components of the clutch hydraulic system before tube disconnection while using a suitable container to catch draining fluids at the clutch master cylinder. Use a 3/32-inch punch to remove the roll pin before discarding it and extracting the O-ring from the hydraulic tube end and sealing the tube with a cap. Insert the new push rod into the clutch master cylinder with the reservoir positioned above the master cylinder to prevent run dry conditions. The master cylinder requires a purge of air through fluid introduction using Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent which meets Ford specification ESA-M6C25-A until fluid reaches the container. Carry out this procedure 2 to 3 times. The end of the hydraulic tube should receive the new O-ring seal and DOT 3 Brake Fluid application before tube attachment to the clutch master cylinder using a new roll pin for installation. Bleed the clutch hydraulic system by using a bench then move the clutch system into the vehicle while routing the hydraulic tube properly and mounting the clutch hydraulic reservoir to the wiring tray. To install the clutch master cylinder you should compress and twist it counterclockwise by 45 degrees until it locks to the clutch pedal and support bracket while ensuring the rubber seal properly sits on the bulkhead and directing the hydraulic tube under the brake booster reservoir. Fasten the power distribution box bracket and ensure the clutch pedal position switch faces the master cylinder tab as its flat side and the switch connector points to 12 o'clock while securing the switch with its cover on the push rod. The installation process requires attaching a new push rod bushing to the push rod while connecting the clutch pedal before elevating the car and safely routing the hydraulic tube and slave cylinder toward the transmission. Finally install the slave cylinder by tightly twisting it onto the transmission. After securing the clutch hydraulic tube to the floor pan clip you should lower the vehicle then connect the tube to dash clip while pushing the clutch pedal to seat the push rod inside the clutch master cylinder before checking system operation.