OEM 2003 Ford Focus Clutch Master Cylinder

2003 Ford Focus Clutch Master Cylinder Parts Q&A

• Q: How to service and repair the clutch master cylinder on the IB5 transaxle on 2003 Ford Focus?

  A: The first step in servicing or repairing the clutch master cylinder of IB5 transaxle consists of disconnecting the battery ground cable. Take necessary precautions to stop brake fluid from touching the vehicle's paintwork because any leak should be cleaned up at once by washing with cold water. Syringe equipment allows you to drain brake fluid pong the reservoir until the MIN mark appears before sealing the cap in place. The first step consists of removing the air cleaner while removing the Central Junction Box (CJB) by deleting the retaining bolt and releasing the clip. Strictly secure fluid supply lines for clutch master cylinder and slave cylinder with caps to block leakage or dirt access before disconnecting them by inserting a thin bladed screwdriver and taking out clips. detach the instrument panel lower panel first by removing screws followed by releasing the fastener then completely remove it while detaching the Data Link Connector (DLC) and disconnecting the hood release cable. Separately detach the clutch slave cylinder supply line at the front bulkhead while taking out its retaining clamp. Depress the locking tang to remove the brake pedal actuating rod retaining pin and disconnect the electrical connectors from the starter safety switch while also disconnecting the connectors from the clutch position switch, speed control deactivation switch and stop lamp switch from the pedal assembly. The pedal assembly must be entirely detached for access to clutch master cylinder retaining bolts. After bolt removal, the pedal assembly can be mounted in a vise while operators slide off the actuating rod from the pedal arm to detach the cylinder. After attaching the pedal arm rod to the clutch master cylinder and the assembly to the pedal assembly you can locate the pedal assembly back into the vehicle. Position the brake pedal actuating rod retaining pin so the locking tab is visible before installing the retaining pin to its holding position. The pedal assembly needs retaining nuts to be affixed before the clutch slave cylinder supply line gets connected to the front bulkhead and receives its clip. Measure the extended lengths of the following plunger-styled switches: speed control deactivation switch (green) should be 24 mm while stop lamp switch (grey) requires 21 mm and the starter safety switch (black) requires 26 mm. Switches should be installed by spinning the stop lamp switch to the left and all others to the right for proper fitting. Proceed in the following sequence when installing the switches: speed control deactivation switch (green) followed by stop lamp switch (grey) then clutch position switch (red) lastly finish with starter safety switch (black). The electrical connectors must be installed to the switches before you can adjust the starter safety switch while pressing and releasing the clutch pedal. Install new O-ring seals before you connect the clutch master cylinder as well as the slave cylinder fluid supply lines while using clips for installation. The hood release cable along with the Data Link Connector (DLC) will be connected to the instrument panel lower panel before the panel trim receives the fastener and screws for installation. You should return the Central Junction Box to its position by using the retaining bolt and clip while reinstalling the air cleaner. End the work order by adding Super DOT 3 brake fluid to the reservoir and conducting hydraulic clutch system bleeding followed by reconnecting the battery ground cable.