Clutch Pedal Assembly: Service and Repair
Removal and Installation1. Note: Disconnect the footwell lamp electrical connector.
Remove the instrument panel insulator.
2. Remove the Clutch Pedal Position (CPP) switch bracket bolts and position the bracket out of the way.
3. Remove the snap ring and disconnect the clutch master cylinder push rod.
4. Note: When the clutch pedal shaft is removed from the bucket, the brake pedal, bake and clutch pedal bushings and the spring washer become accessible.
Remove the clutch pedal snap ring and the clutch pedal shaft.
5. Remove the clutch pedal return spring and the clutch pedal.
6. Note: Position the return spring in the "V" at the top of the pedal arm.
Note: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the brake and clutch pedal bushings. Clean and lubricate with a light film of Super Premium SAE 5W-30 Motor Oil or equivalent meeting Ford specification WSS-M2C153-G and install a new bake and clutch pedal bushing if excessive wear is evident.
To install, reverse the removal procedure.
Clutch Master Cylinder
Removal and Installation
1. Note: Disconnect the footwell lamp electrical connector.
Remove the instrument panel insulator.
2. Remove the Clutch Pedal Position (CPP) switch bracket bolts and position the bracket out of the way.
3. Remove the snap ring and disconnect the clutch master cylinder push rod.
4. Remove the snap ring.
5. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If the brake fluid is spilled onto a painted or plastic surface, wash it immediately with water.
Disconnect the clutch hydraulic line from the elbow.
6. Remove the nuts and the clutch master cylinder.
7. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If the brake fluid is spilled onto a painted or plastic surface, wash it immediately with water.
Remove the hose at the clutch master cylinder reservoir.
8. CAUTION: Clean all rubber clutch master cylinder parts with dean High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.
Clean all clutch master cylinder components.
9. Inspect the clutch master cylinder for the following:
- weak spring
- damage to any reservoir components
- damaged cups
- scored piston
10. To install, reverse the removal procedure.
- Bleed the clutch hydraulic system.