OEM 2002 Ford Focus Clutch Master Cylinder

2002 Ford Focus Clutch Master Cylinder Parts Q&A

• Q: How to service and repair the clutch master cylinder on the IB5 manual transaxle on 2002 Ford Focus?

  A: The clutch master cylinder repair process starts with detaching the battery ground cable on vehicles that use IB5 manual transaxle. Brake fluid must be avoided from touching paint surfaces. Any resulting fluid leakage needs immediate response with cold water for cleaning. A recommended syringe should be used to extract brake fluid until the MIN mark shows from the reservoir before reattaching its cap. First remove the air cleaner then unplug the Central Junction Box (CJB) when you remove its retaining bolt followed by releasing the clip. Opening access to fluid supply lines of both clutch master and slave cylinders requires thin bladed screwdrivers along with clips removal for disconnecting them. After removing the screws and releasing the fastener from the instrument panel lower panel the entire panel plus DLC connector and hood release cable must be taken off. Users need to extract the clutch slave cylinder supply line from the front bulkhead and remove the fastener holding the clip. Perl the locking tang to remove the brake pedal actuating rod retaining pin before disconnecting all the electrical connectors that link the starter safety switch, clutch position switch, speed control deactivation switch and stop lamp switch from the pedal assembly and switching out the switches. The complete pedal assembly needs to be removed to access the clutch master cylinder retaining bolts so you can mount the assembly in a suitable vise, remove the bolts and detach the cylinder from the pedal assembly with the actuating rod sliding off the pedal arm. To install the parts assemble the actuating rod with the pedal arm while connecting the clutch master cylinder to the pedal assembly followed by placing the complete pedal assembly inside the vehicle. Install the brake pedal actuating rod retaining pin after making sure that both the locking tab displays outside and the pin remains in its fixed state. Install the pedal assembly retaining nuts before you attach the clutch slave cylinder supply line to the front bulkhead and place its clip. Stretch the plungers of the safety starter (black) and speed control deactivation (green) and stop lamp (gray) switches fully until you reach their complete length. The deactivation switch needs to extend to 24mm while stop lamp requires a 21mm stretch and the safety starter stretches to 26mm. The installation process requires turning the stop lamp switch counter-clockwise but doing the other switches in a clockwise direction to prevent binding. The installation sequence demands placing the speed control deactivation switch (green) first then moving to the stop lamp switch (gray) followed by the clutch position switch (red) and ending with the starter safety switch (black). Attach electrical connectors to the switches before adjusting the starter safety switch through a clutch pedal operation. After replacing O-ring seals you should complete the procedure by joining clutch master cylinder and slave cylinder fluid supply lines while attaching their respective clips. Reinstall the hood release cable and DLC to their locations on the instrument panel lower panel while securing the trim with fastener and screws. Screw the retaining bolt into the mounting bracket where CJB will be placed before fastening the clip over it. As the last step install the air cleaner then add Super DOT 3 brake fluid to the reservoir followed by bleeding the hydraulic clutch system and battery cable reattachment.