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Old 06-11-2019, 12:45 AM   #1
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Clutch pedal suddenly goes to floor !!!

Only returns via return spring !
What broke ??? 2002 zetec 2.0 manual.
Has been working perfectly.
Slave cylinder? Hydraulic line ?
Got it out of traffic by starting it in gear.

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Old 06-11-2019, 01:20 AM   #2
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Hydraulic fail likely.
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Old 06-11-2019, 07:35 AM   #3
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X2 for hydraulics. Easy to pinpoint - it's only three parts.
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Old 06-11-2019, 08:20 AM   #4
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X2 for hydraulics. Easy to pinpoint - it's only three parts.
But the DAMNED slave is inside !!! Ford better idea. Trans. has to come out.
I'm praying it is master or the line.

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Old 06-11-2019, 08:24 AM   #5
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Hydraulic fail likely.
I was "saving the manuals" now I'm crying.
I have been noticing squeaking during clutch use for a few weeks. Might the cheap PLASTIC mechanism have failed. Saw a video. Ford made it out of PLASTIC... The whole thing !!!

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Old 06-11-2019, 11:24 AM   #6
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I was "saving the manuals" now I'm crying.
You'd be crying if your $$$ auto trans had failed as well. Sorry, man.
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Old 06-11-2019, 01:04 PM   #7
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Don't cry. I can change the clutch out in 6 hours. Easier to pull the subframe imho. Good time to refresh your steering rack and sway bar mounts. Why pull the subframe you ask? The transaxle goes in and out without twisting to clear the subframe and the other reasons I listed above. Additionally. That plastic part lasted 17 years. Pretty impressive imho.
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Old 06-11-2019, 04:35 PM   #8
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Don't cry. I can change the clutch out in 6 hours. Easier to pull the subframe imho. Good time to refresh your steering rack and sway bar mounts. Why pull the subframe you ask? The transaxle goes in and out without twisting to clear the subframe and the other reasons I listed above. Additionally. That plastic part lasted 17 years. Pretty impressive imho.
If it is the slave my retired mechanic friend...dealer mechanic for several brands , does jobs for a fraction of the independent shop price.
Is it a GOOD sign I saw no fluid leaking from trans. area ?
BTW he diagnosed my DPFE and purge valve codes with his bidirectional high dollar scanner for a six pack. Got used parts at local yard for a few dollars...FIXED.
He put in my new MOOG sway bar end links and new fender liner for $20
Changed out my trans. fluid ...Ford special oil... for a sixer. Hoping clutch fix isn't too bad.
Other stuff I got at yard...
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Old 06-11-2019, 04:40 PM   #9
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Quote:
Originally Posted by pbfoot View Post
Don't cry. I can change the clutch out in 6 hours. Easier to pull the subframe imho. Good time to refresh your steering rack and sway bar mounts. Why pull the subframe you ask? The transaxle goes in and out without twisting to clear the subframe and the other reasons I listed above. Additionally. That plastic part lasted 17 years. Pretty impressive imho.
If it is the slave my retired mechanic friend...dealer mechanic for several brands , does jobs for a fraction of the independent shop price.
Is it a GOOD sign I saw no fluid leaking from trans. area ?

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Check the clutch master cylinder. It is on the clutch pedal inside the car. To diagnose . Have someone help you bleed the clutch. If no fluid comes out of the bleeder on top of the transaxle, the master cylinder is bad. Not too hard to replace. Another possibility is your clutch and brake pedal bushings are worn and let the master cylinder arm pop off the clutch pedal arm. Easy fix as well. Check it.
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Old 06-11-2019, 05:13 PM   #10
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Check the clutch master cylinder. It is on the clutch pedal inside the car. To diagnose . Have someone help you bleed the clutch. If no fluid comes out of the bleeder on top of the transaxle, the master cylinder is bad. Not too hard to replace. Another possibility is your clutch and brake pedal bushings are worn and let the master cylinder arm pop off the clutch pedal arm. Easy fix as well. Check it.
I think the arm popped off !!! That's the way it acted !!! Been squeaking for weeks. I think you nailed it. My friend when he changed my fluid said old fluid was like new and he could tell the case had been opened. I'm sure the clutch and slave/throwout bearing combo part was replaced as well as synchros etc. that needed replacing.
Are bushings sold separately? If not I can get part used for now. Yard near me has 3 or 4 manual cars...thats how I got this knob for $1.79
Mine was worn and shift pattern was missing.
I also found a complete set of books with unopened 2002 FOCUS CD as well as zippered case.
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