OEM Ford F-250 Super Duty Clutch Master Cylinder

Ford F-250 Super Duty Clutch Master Cylinder Parts and Q&A

• Master Cylinder
  3C3Z-7C522-B
  Q: How to remove and replace the clutch master cylinder on Ford F-250 Super Duty?

  A:

  Before clutch master cylinder replacement begin by disconnecting the clutch hydraulic tube from its dash installation point. The vehicle should rest on a hoist with transmission in neutral position. To uninstall the slave cylinder attached to transmission in 5.4L and 6.8L clutch systems, users should pull back the heat shield while unlocking the clutch cylinder before rotating it counterclockwise for removal. You should disconnect the clutch hydraulic tube at the floor pan clip and move the Clutch Slave Cylinder and accompanying tube in front of the left engine bank to minimize tube tension. You must lower the vehicle then unlock the push rod retaining clips so the clutch master cylinder push rod can be removed from the clutch pedal but discard the push rod bushing. The first step requires removal of the switch cover combined with the clutch pedal position switch from the push rod before separating the power distribution box from its bracket to reach the clutch master cylinder. The clutch master cylinder needs to be removed after unlocking it through a clockwise compression and twisting process of 45 degrees. Pay attention to the brake fluid because it will damage painted and plastic surfaces so immediately clean away any liquid with water. Use the clutch pedal position switch's flat side to attach it to the tab on the new master cylinder and position the switch wiring connector at 12 o'clock so the clutch pedal operates correctly and maintains safety. During installation reverse the removal actions by fitting a new push rod bushing while correctly placing the push rod inside the master cylinder. The heat shield should be moved toward the slave cylinder until it reaches the transmission case for both 5.4L and 6.8L systems. To validate system operation you should first press down on the clutch pedal until the push rod establishes its position inside the master cylinder.
• Master Cylinder
  F81Z-7A543-FA
  Q: How to service and repair the clutch master cylinder and reservoir on Ford F-250 Super Duty?

  A:

  The repair and servicing of the clutch master cylinder together with its reservoir requires full removal of the entire clutch hydraulic assembly from the vehicle before installing a new clutch master cylinder assembly. Users must disconnect the clutch hydraulic tube from the dash clip and then support the vehicle before removing the slave cylinder from the transmission through compression and twisting movements to unlock it. The clutch hydraulic tube should be disconnected from its floor pan clip to let the slave cylinder and hydraulic tube drop forward beside the left engine bank before the clutch master cylinder is separated from its clutch pedal and support bracket. Lower the vehicle to access the clutch master cylinder push rod while removing the retaining clips that secure both push rod bushings. The push rod should be separated from the clutch pedal before discarding the bushing unit. You must first remove the switch cover together with the clutch pedal position switch from the clutch master cylinder push rod and disconnect the power distribution box from its bracket for clutch master cylinder access. Follow the procedure to extract the clutch master cylinder from the pedal assembly while angling it at 45 degrees clockwise orientation. Locate the clutch reservoir from its wiring tray position then disconnect the hydraulic tubing between the Brake Master Cylinder assembly and bring the reservoir to a separate location. After cleaning the clutch hydraulic system parts for contaminant prevention the technician must set down a suitable containment container before removing the hydraulic tube. To detach the hydraulic tube from the clutch master cylinder start by driving out the roll pin with a 3/32-inch punch and finally disposing of the pin before tube detachment. Cut the O-ring seal off from the hydraulic tube end before placing a cover on the open tube tip. Install the new push rod to the clutch master cylinder but keep the master cylinder reservoir elevated above its location while filling the assembly with Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent that meets Ford specification ESA-M6C25-A. Fill the reservoir twice or thrice to purge all air and then install the reservoir cap and master cylinder port cap. Install the new O-ring seal at the hydraulic tube end before coating it with DOT 3 Brake Fluid and using it to connect the clutch master cylinder. Also secure the hydraulic tube with a new roll pin installed. Position the clutch hydraulic system in the vehicle while bleeding the hydraulic system bench and correctly route the hydraulic tube before attaching the clutch hydraulic reservoir to the wiring tray. The clutch master cylinder requires installation by using counterclockwise torque to twist it 45 degrees until it locks to both the clutch pedal and support bracket while maintaining the O-ring position against the bulkhead. The clutch master cylinder-to-slave cylinder hydraulic tube should run under the brake booster reservoir and the power distribution box needs to be attached to the bracket. Apply the clutch pedal position switch to the clutch master cylinder push rod with its flat side directed towards the clutch master cylinder tab and its wiring connector positioned at 12 o'clock, then fasten it using the switch cover. Secure the new push rod bushing afterward connecting the clutch master cylinder push rod to the clutch pedal followed by vehicle suspension and proper routing of hydraulic tube and slave cylinder to the transmission and finish the installation by compressing and twisting the slave cylinder to secure its placement against the transmission. Lower the vehicle and perform testing for system operation after connecting the clutch hydraulic tube to the floor pan clip and the dash clip and pressing the clutch pedal to push the rod into the clutch master cylinder.