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 those equipped with the MT285/MTX-75 manual transaxle on 2002 Ford Focus?

  A: Before maintaining or fixing the clutch master cylinder on cars with MT285/MTX-75 manual transaxle units start by removing the ground cable from the battery. Make sure to avoid allowing brake fluid contact with vehicle paint since immediate cold water cleaning of the affected area represents the appropriate response to fluid spills. There are suitable syringes available to drain brake fluid from the reservoir up to the MIN mark before reinstalling the cap. First separate the Central Junction Box (CJB) by unbolted the retaining fastener and unclipping the bracket before removing the air cleaner. The fluid supply lines belonging to master cylinder and slave cylinder must be capped against fluid loss and dirt intrusions before using a thin screwdriver to disconnect them and remove their retaining clips. The instrument panel lower panel needs screws removal to access its fastener for panel disconnection and immediate Data Link Connector (DLC) and hood release cable separation. The first step requires detachment of the clutch slave cylinder supply line from the front bulkhead while removing the associated clip. The pedal assembly requires removal of the brake actuating rod retaining pin by depressing its locking tang to access all the electrical connectors for the starter safety switch, clutch position switch, speed control deactivation switch and stop lamp switch. The connectors can be removed once these switches are unplugged. A vise must support the pedal assembly to gain access to the clutch master cylinder retaining bolts. After bolt retention the assembly should be detached to remove the clutch master cylinder before pulling the actuating rod off its pedal arm. The actuating rod should be placed onto the pedal arm while clamping down the clutch master cylinder on the pedal assembly until you can reinstall it into the vehicle. The brake pedal actuating rod retaining pin needs installation after being set into locked position where its locking tab is visible. Then install the retaining nuts. Secure the clutch slave cylinder supply line installation at the front bulkhead after adding the required clip. To adapt the plunger lengths, fully extend the speed control deactivation switch to 24 mm, stop lamp switch to 21 mm and the starter safety switch to 26 mm. During installations of these components fit the stop lamp switch first with counter-clockwise rotation then proceed with clockwise rotation for the other two switches to stop binding. For the electrical connection of the switches install the starter safety switch after pressing and releasing the clutch pedal then optionally replace O-ring seals when needed. The fluid supply lines must be connected to the clutch master cylinder before fastening the clips in place. Place the hood release cable and DLC into the instrument panel lower panel before installing new trims followed by attaching the CJB using its retaining bolt and clip. Put on the air cleaner before you finish the procedure by adding Super DOT 3 brake fluid to the brake fluid reservoir and performing a hydraulic clutch system bleed operation. Reinstall the battery ground cable at the end.