"How To" - Clutch Master Cylinder Replacement

[pokeySVT]

Well I just finished this repair on my 02 SVTF. While it was not fun, it was not nearly as difficult as some people lead me to believe. I thought that it might be good to have a list of tips and tricks that I used for others in case anyone wants to attempt this repair.

(1). I started by removing my airbox and intake tube (I left the MAFS alone)
(2). Then I unclipped the fuse box from the fire wall and pulled it towards the front of the car to let me access the clutch hydralic lines.
(3). Move to the inside of the vehicle and remove the clutch pedal position sensor and the clutch interlock sensor.
(4). Unbolt the master cylinder from the pedal assembly bracket, a metric sized GearWrench will greatly speed up this process.
(5). Once the master cylinder was unbolted from the pedal assembly bracket I loosen the entire pedal assembly bracket, there are four nuts that need to be loosened and a looong extension will allow access to the top two.
(6). With the bracket loosened I moved back to the engine compartment and unbolted the junction block (where the lines pass through the fire walll), then I removed the clips that hold the hydralic lines in place.
(Tip!!) Here is a little trick to help stop fluid loss from the resevior, I pulled the rubber cap off of the clutch bleeder screw and put it on the line that runs from the resevior to the master cylinder.
(7). I found that it was easier to push the master cylinder back into the car as I removed the lower clutch line.
(Tip!!) Here is the second tip that I learned, make sure that you put the lower line back into the master cylinder before you bolt the master cylinder to anything.
(8). Reinstall in reverse order and have a friend help bleed the system.

All in all it took me about 1.5 hours to complete the repair, and I think that it is well within an average mechanics abilities, no special tools required.!!

[Sponsor]

[Portuga]

Did you get the newer updated part, the one that doesn't break down for no reason?
If so, what is the part number so I can order it?

[pokeySVT]

I was not aware that there was an updated part #, I just got mine from the local Ford store. I will look-up the part number that I got and let you know

[WD40]

It's a "sticky".

[pokeySVT]

Originally posted by Portuga
Did you get the newer updated part, the one that doesn't break down for no reason?
If so, what is the part number so I can order it?

Sorry about the delay, here is the part number that I used. 1M5Z-7A543-AA

hope that helps

[skicat]

This is a great post and much appreciated. Just a few of questions:

What is a GearWrench?

Did you bleed the system from the master? slave? both?

Where is the slave cylinder located?

Thanx for yr help.

[elwood125]

the part # for an 00-01 is the ys4z-7a543-aa



is the 1m5z an improved part??


is clutch pedal travel a problem you have when this fails??

[b16sir1991]

That YS4Z# is for an early 2000-'01 model. 1M5Z-9A543-AB is the later one.

[b16sir1991]

Your part# superceeds to a 98AB-9A543-AH for the early ones.

[elwood125]

so they are not interchangeable? I am still having clutch pedal travel issues and after replacing the clutch and slave cylinder, flywheel am getting a little panicky. any help advice would be nice.


elwood125@hotmail.com