The complete clutch hydraulic system requires removal as one unit before performing any repair work on the new master cylinder-to-slave cylinder hydraulic tube. The service begins with clip removal from the dash of the clutch hydraulic tube followed by vehicle elevation and support. This allows the slave cylinder unlocking by compression and twisting then transmission removal. It is crucial to position the slave cylinder and hydraulic tube forward below the left engine bank after disconnecting the floor pan clip from the clutch hydraulic tube to minimize hydraulic tube tension. You need to lower the vehicle to access the push rod bushing retaining clips which will let you detach the
Clutch Master Cylinder push rod from the clutch pedal before discarding the push rod bushing. The technicians must detach the clutch pedal position switch and switch cover from the clutch master cylinder push rod before they separate the power distribution box from its bracket for clutch master cylinder access. The clutch master cylinder needs to be twisted clockwise by 45 degrees while being compressed before removal followed by unhooking the clutch hydraulic reservoir from its place in the wiring tray and pulling apart the hydraulic tube from the
Brake Master Cylinder assembly. The user needs to exercise caution because brake fluid damages painted and plastic surfaces yet water immediately clears the spillage. A suitable container should be placed below the master cylinder before you disconnect the hydraulic tube by using a 3/32-inch punch and hammer to drive out the roll pin. All components need cleaning to avoid system contamination. Follow this method to clean the slave cylinder while taking out and disposing of any present O-rings from its internal area. Install the hydraulic tube by placing new O-ring seals with coating of Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equal to ESA-M6C25-A on the end of the tube. Then connect the tube to both the clutch master cylinder and secure the roll pin for installation. Position the components in a specific way to keep the reservoir elevated above the master cylinder and the hydraulic tube located beneath it thus preventing the reservoir from running dry as air escapes from the system. Add fluid to the reservoir after which you must run master cylinder fluid before repeating the process until all air is removed from the system. You should hold the slave cylinder above a proper container at an angle which shows the hydraulic tube connection port above the push rod as you fill it with DOT 3 brake fluid. Connect the hydraulic tube to its slave cylinder port by sliding a new O-ring onto the opening and wetting it with brake fluid then putting the tube in position while installing the roll pin to secure it. The technician will bench bleed the clutch hydraulic system followed by installing it into the vehicle with proper routing of the hydraulic tube while attaching the clutch hydraulic reservoir to the wiring tray. Attach the clutch master cylinder by applying force to compress it while twisting it counterclockwise to 45 degrees so it locks to the clutch pedal and support bracket maintaining proper orientation of the rubber seal to the bulkhead. Install the clutch pedal position switch onto the clutch master cylinder push rod where its flat side should point toward the tab on the master cylinder at a 12 o'clock position with the switch covered secure. Insert the new push rod bushing into place before attaching the clutch master cylinder push rod to the clutch pedal and raise and support the vehicle before directing the hydraulic tube and slave cylinder to the transmission correctly. Proceed to install the slave cylinder by twisting and compressing it to lock it onto the transmission. The system should be tested for normal operation after connecting the clutch hydraulic tube both to the floor pan and dash clips while lowering the vehicle.