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Clutch Slave Cylinder > < Clutch Controls

Focus 2004.75 (07.2004-)

Clutch Controls - Vehicles With: 6-Speed Manual Transmission (MMT6) - Clutch Master Cylinder Focus 2004.75 (07/2004-)
Removal and Installation

Special Tool(s)

Remover/Installer, Clutch Master Cylinder

308-554
Materials
Name
Specification
Grease
WSD-M1C230-A
CAUTION:
CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
All vehicles
  1. Remove the air cleaner. For additional information, refer to: (303-12 Ansaugsystem)
    Luftfilter - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (Removal and Installation),
    Luftfilter - 1.6L Duratec-16V Ti-VCT (Sigma) (Removal and Installation),
    Luftfilter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation),
    Luftfilter - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation),
    Luftfilter - 2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation),
    Luftfilter - 1.6L (Z6) (Removal and Installation).
Left-hand drive vehicles
  1. Remove the battery carrier. For additional information, refer to: (414-01 Batterie, Befestigung und Batteriekabel)
    Batteriekonsole - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation),
    Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation).
RHD vehicles
  1. Disconnect the battery.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
All vehicles
  1. Extract brake fluid from the brake fluid reservoir until the level reaches the MIN mark.

  1. Remove the lower footwell trim.

  1. Detach the data link connector (DLC) from the footwell lower trim.
    • Detach the data link connector clips.

  1. Detach the steering column shaft joint from the steering.
    • Unscrew and remove the steering column shaft joint bolt and discard.

8. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Clutch master cylinder pipes.
See Removal Detail
2
-
Clutch pedal return spring(vehicles with 1.4L, 1.6L, 1.8L, 2.0L engines shown)
3
-
Nuts, clutch pedal bracket
See Removal Detail
4
-
Clutch pedal bracket
See Removal Detail
5
-
Catch for clutch master cylinder actuating rod
See Removal Detail
6
-
Clutch master cylinder
See Installation Detail

9. To install, reverse the removal procedure.

All vehicles
WARNING:
WARNING:Install a new steering column shaft joint bolt. Failure to follow this instruction may result in personal injury.
  1. Attach the steering column shaft joint to the steering.
    • Tighten the steering column shaft joint bolt.

  1. Attach the data link connector (DLC) at the footwell lower trim.
    • Install the data link connector clips.

  1. Install the lower footwell trim.
  1. Bleed the clutch system.
    For additional information, refer to: Kupplungssystem entlüften (308-00 Schaltgetriebe und Kupplung - Allgemeine Informationen, General Procedures).
Left-hand drive vehicles
  1. Install the battery carrier. For additional information, refer to: (414-01 Batterie, Befestigung und Batteriekabel)
    Batteriekonsole - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation),
    Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation).
RHD vehicles
  1. Connect the battery.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
All vehicles
  1. Install the air cleaner. For additional information, refer to: (303-12 Ansaugsystem)
    Luftfilter - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (Removal and Installation),
    Luftfilter - 1.6L Duratec-16V Ti-VCT (Sigma) (Removal and Installation),
    Luftfilter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation),
    Luftfilter - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation),
    Luftfilter - 2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation),
    Luftfilter - 1.6L (Z6) (Removal and Installation).
Vehicles with global closing
  1. Initialize the window regulator motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Removal Details

Item 1 : Clutch master cylinder pipes.

  1. NOTE:
    NOTE:The next step should only be performed on RHD vehicles.
    Raise the vehicle for access For additional information, refer to: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Jacking (Description and Operation).

  1. CAUTION:
    CAUTION:Close off the clutch master cylinder line to prevent fluid loss or dirt ingress.
    Detach the clutch master cylinder pipes from the clutch master cylinder.
    1. Press the clutch master cylinder supply line lock button.
    1. Remove the clutch slave cylinder pressure line securing clip.
  1. NOTE:
    NOTE:The next step should only be performed on RHD vehicles.
    Lower the vehicle.

Item 3 : Nuts, clutch pedal bracket
  1. Remove the clutch pedal bracket nuts.
    • Discard the nuts.

Item 4 : Clutch pedal bracket
  1. Detach the clutch pedal position (CPP) switch from the clutch pedal bracket.
    • Detach the cable from the wiring harness bracket.

  1. Detach the clutch master cylinder from the bulkhead using the special tool.
    • Turn the clutch master cylinder 60 degrees counter-clockwise.

  1. Remove the clutch master cylinder together with the clutch pedal bracket.
    • Turn the clutch pedal bracket to the position shown.

Item 5 : Catch for clutch master cylinder actuating rod
  1. Detach the clutch master cylinder from the clutch pedal bracket.
    • Press together the catch for the clutch master cylinder actuating rod.

Installation Details

Item 6 : Clutch master cylinder
  1. NOTE:
    NOTE:Coat the clutch master cylinder gaiter with grease before installing.
    Install the clutch master cylinder.

Clutch Slave Cylinder > < Clutch Controls