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308-02 Clutch Controls|Specifications > < Clutch Slave Cylinder

Fusion 2002.75 (06.2002-)

Clutch Controls - Clutch Master Cylinder Fusion 2002.75 (06/2002-)
Removal and Installation

Removal

CAUTION:
CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
All vehicles
  1. Using a suitable syringe, remove brake fluid from the brake fluid reservoir until the brake fluid level is at the MIN mark.
Right-hand drive vehicles
  1. Remove the air cleaner. For additional information, refer to: (303-12 Intake Air Distribution and Filtering)
    Air Cleaner - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (Removal and Installation),
    Air Cleaner - 1.3L Duratec-8V (Rocam) (Removal and Installation),
    Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation),
    Air Cleaner - 2.0L Duratec-HE (MI4) (Removal and Installation),
    Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation).
Left-hand drive vehicles
  1. Disconnect the two vacuum hoses.
    • Detach the vacuum hoses from the battery clamp clip.
  1. Remove the battery tray. For additional information, refer to:
    Battery Tray (414-01, Removal and Installation),
    Battery Tray - 2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).
All vehicles
  1. NOTE:
    NOTE:Plug the brake fluid reservoir to prevent fluid loss or dirt ingress.
    Disconnect the clutch master cylinder supply hose from the brake fluid reservoir.
    • Push the clip to release the clutch master cylinder supply hose.

  1. Remove the clutch master cylinder supply hose.
    • Release the clutch master cylinder supply hose retaining clip.
    • Allow the fluid to drain into a suitable container.

  1. NOTE:
    NOTE:Plug the clutch slave cylinder supply line to prevent fluid loss or dirt ingress.
    Disconnect the clutch slave cylinder supply line from the clutch master cylinder and position it to one side.
    • Release the clutch slave cylinder supply line retaining clip.

  1. Remove the clutch master cylinder retaining bolts.

  1. NOTE:
    NOTE:Remove the clutch master cylinder and the clutch pedal as an assembly.
    Remove the clutch master cylinder and the clutch pedal assembly.
    • Remove the pedal pivot shaft retaining nut and remove the pivot shaft.
    • Rotate the clutch master cylinder and clutch pedal assembly counterclockwise.

  1. Remove the clutch master cylinder.
    1. Remove the clutch pedal return spring.
    1. Detach the clutch master cylinder actuating rod from the clutch pedal.

Installation

All vehicles
  1. NOTE:
    NOTE:Using suitable tape, secure the clutch pedal return spring in position.
    Install the clutch master cylinder.
    1. Attach the clutch master cylinder actuating rod to the clutch pedal.
    1. Install the clutch pedal return spring.

  1. NOTE:
    NOTE:Install the clutch master cylinder and the clutch pedal as an assembly.
    Install the clutch master cylinder and the clutch pedal assembly.
    • Rotate the clutch master cylinder and the clutch pedal assembly clockwise.
    • Install the pedal pivot shaft.

  1. Install the clutch master cylinder retaining bolts.

  1. Connect the clutch slave cylinder supply line to the clutch master cylinder.
    • Install the clutch slave cylinder supply line retaining clip.

  1. Connect the clutch master cylinder supply hose to the clutch master cylinder.
    • Install the clutch master cylinder supply hose retaining clip.

  1. Connect the clutch master cylinder supply hose to the brake fluid reservoir.
  1. Bleed the clutch system. For additional information, refer to: (308-00 Manual Transmission/Transaxle and Clutch - General Information)
    Clutch System Bleeding (General Procedures),
    Clutch System Bleeding - Vehicles With: Automated Gearshift (General Procedures).
Left-hand drive vehicles
  1. Install the battery tray. For additional information, refer to:
    Battery Tray (414-01, Removal and Installation),
    Battery Tray - 2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Connect the two vacuum hoses.
    • Attach the vacuum hoses to the battery clamp clip.
Right-hand drive vehicles
  1. Install the air cleaner. For additional information, refer to: (303-12 Intake Air Distribution and Filtering)
    Air Cleaner - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (Removal and Installation),
    Air Cleaner - 1.3L Duratec-8V (Rocam) (Removal and Installation),
    Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation),
    Air Cleaner - 2.0L Duratec-HE (MI4) (Removal and Installation).

308-02 Clutch Controls|Specifications > < Clutch Slave Cylinder