OEM 2003 Ford F-350 Super Duty Clutch Master Cylinder

2003 Ford F-350 Super Duty Clutch Master Cylinder Parts Q&A

• Q: How to service and repair the clutch master cylinder and reservoir on 2003 Ford F-350 Super Duty?

  A: The first step for clutch master cylinder and reservoir servicing includes complete clutch hydraulic system removal as an assembly during new clutch master cylinder assembly installation. The clutch hydraulic tube must be dismounted from its dash clip before vehicle elevation and transmission slave cylinder removal by using compression and twisting to unlock it from the transmission. The floor pan clip must be removed from the clutch hydraulic tube while the slave cylinder and tube get positioned in front of the left bank to ease hydraulic tube strain. The technical step begins with bushing clip removal to separate clutch pedal and push rod connection. Then discard the push rod bushing. The technician needs to remove the switch cover and clutch pedal position switch from the clutch master cylinder push rod as they disconnect the power distribution box from its bracket. The technician must unlock the clutch master cylinder from its position in the pedal and support bracket through counterclockwise twisting compression of 45 degrees. To begin the procedure either place 5.4L, 6.8L and 7.3L hydraulic reservoirs aside the wiring tray or disconnect the tube between the clutch and brake master cylinder for 6.0L models. Brake fluid poses risks to painted and plastic materials so quickly wash the affected areas using water if fluid spills occur. Clean all pieces in the clutch hydraulic system before disconnecting the hydraulic tube while you position an appropriate container to catch any fluid. A 3/32-inch punch along with a hammer should be used to drive out and discard the roll pin followed by removing the O-ring seal from the hydraulic tube end while capping the open end. To install the new push rod place it within the clutch master cylinder while maintaining reservoir fluid level above the master cylinder so dry out is avoided. You should drain air from the clutch master cylinder assembly while filling the reservoir with brake fluid until the fluid passes through the master cylinder and into the container and repeat the draining procedure from 2 to 3 times. Installation involves placing the new O-ring seal on the hydraulic tube end point while applying brake fluid to the surface before tube attachment to the clutch master cylinder through new roll pin installation. Position the system into the vehicle while checking that the tube links reservoir and master cylinder properly to prevent air entrapment. The procedure requires attaching the clutch hydraulic reservoir followed by cylinder master installation through counter-clockwise twisting while compressing until it locks into place with the clutch pedal and support bracket. Afterward, position the rubber bulkhead seal into its correct position. After routing the hydraulic tube under the brake booster reservoir reinstall the power distribution box to the bracket while mounting the clutch pedal position switch with its flat side facing the clutchmaster cylinder tab located at the 12 o'clock wire connector position which needs to be covered with the switch casing. Begin by installing the new push rod bushing then connect its rod to the pedal before supporting the vehicle and properly routing tubes to the transmission and compressor installation by twisting the slave cylinder until lock is achieved. The floor pan clip connects to the clutch hydraulic tube first, then the vehicle should be lowered, before connecting the tube to the dash clip and pressing the clutch pedal to locate the push rod inside the master cylinder. Finally, check that the system operates correctly.