OEM 2004 Ford Focus Clutch Master Cylinder

2004 Ford Focus Clutch Master Cylinder Parts Q&A

• Q: How to service and repair the Clutch Master Cylinder on 2004 Ford Focus?

  A: Service and repair operations on the Clutch Master Cylinder should begin by removing the battery ground connection. Maintain attention when avoiding brake fluid connections with paint while you need to clean affected areas right away with cold water in case of leakage. Brake fluid removal using a syringe should continue until the MIN line is reached before reattaching the reservoir cap. Service begins by taking off the air cleaner while unfastening the Central Junction Box (CJB) with bolt removal followed by clip release. Cork the clutch master cylinder and slave cylinder fluid supply lines to stop fluid leakage while protecting it from dirt entry. After using a skinny bladed screwdriver to free these lines you should remove the retaining clips. Detach the instrument panel lower panel first by unscrewing the panel screws and unfastening the retaining holder before taking out the Data Link Connector (DLC) as well as the hood release cable. The clutch slave cylinder supply line needs detachment at its front bulkhead location before removing the clip. Begin replacing the brake pedal actuating rod retaining pin by activating its locking tang then disconnect the electrical connectors which service the starter safety switch as well as the clutch position switch and speed control deactivation switch and stop lamp switch from the pedal assembly. Save the speed control deactivation switch which is green and the stop lamp switch which is grey and also keep the clutch position switch red and starter safety switch black. The complete pedal assembly removal enables access to clutch master cylinder retaining bolts and allows the pedal assembly to rest in a vise while unbolting the retaining bolts which enables the master cylinder detachment from the pedal assembly and rod removal from the pedal arm. The installation process begins with the pedal arm receiving the actuating rod and the clutch master cylinder joining with the pedal assembly after which the pedal assembly should be placed inside the vehicle. Fit the brake pedal actuating rod retaining pin until the locking tab becomes visible and ensure its proper locking position before installation. The pedal assembly needs to be fastened with retaining nuts while installing the clutch slave cylinder supply line to the front bulkhead before attaching the clip. Extend and measure each switch plunger until fully out: speed control deactivation switch is 24mm long and stop lamp switch is 21mm long while starter safety switch reaches 26mm in length. The correct switch installation method requires installing the stop lamp switch counterclockwise but installing the remaining switches with clockwise rotation to prevent any binding. The proper sequence for installing vehicle switches includes the speed control deactivation switch (green), stop lamp switch (grey), clutch position switch (red) and starter safety switch (black). Fix the electrical connectors to the switches followed by adjusting the starter safety switch through clutch pedal activation and release. Nitrided or newly installed O-ring seals must be placed at the clutch master cylinder and slave cylinder fluid supply lines before inserting the proper clips. Reinstall the hood release cable and Data Link Connector to their locations on the instrument panel lower panel while using screws and fasteners to secure the panel trim. Follow the process of reconnecting the CJB with its retaining bolt installation along with clip attachment followed by returning the air cleaner to its position. After filling the brake fluid reservoir with Super DOT 3 brake fluid and performing clutch system bleeding the mechanic will complete the work by reinstalling the battery ground cable.