Clutch Master Cylinder MTX-75

Name	Specification
Brake fluid (Super DOT 4)	ESD-M6C57-A

Removal

1. Standard preparatory operations:

• Please mark the radio key code.
• Mark the preset radio stations.

WARNING: Avoid contact with skin or eyes with brake fluid. If brake fluid comes into contact with skin or eyes, rinse the affected area with water immediately. Failure to follow these instructions may result in injury.

CAUTION: If brake fluid comes into contact with the vehicle's paintwork, immediately wash the affected areas with water.

CAUTION: Disconnect the battery ground cable.

2. Empty the brake fluid reservoir.

3. Remove the air filter housing (shown is the version with the 2.0l Zetec-E engine with the MTX 75 manual transmission).

• 1. Disconnect the mass air flow (MAF) sensor electrical connector.
• 2. Disconnect the positive crankcase ventilation hose.
• 3. Disconnect the inlet hose.

4. Remove the central junction box (CJB). Screw on the left, clamp on the right



5. Disconnect the lines from the clutch master cylinder.

• 1. Remove the clamps.
• 2. Remove the high pressure line from the bracket.

6. Remove the lower instrument panel cover (four screws) and footwell trim panel (clips).



7. Remove the clutch master cylinder.

• 1. Remove the clamp.
• 2. Remove the bolts.
• 3. Release the clutch master cylinder from the pedal support.
• 4. Disconnect the piston rod from the clutch pedal.

Installation

1. Install the clutch master cylinder.

• 1. Connect the piston rod to the clutch pedal.
• 2. Secure the clutch master cylinder to the pedal support.
• 3. Insert the clamp.
• 4. Tighten the bolts.

2. Connect the lines to the clutch master cylinder.

• 1. Insert the clamps.
• 2. Insert the high pressure line into the bracket.

3. Install the instrument panel lower cover (four screws) and footwell trim panel (clips).



4. Connect the CJB. Screw on the left, clamp on the right




5. Install the air filter.

• 1. Install the inlet hose.
• 2. Connect the crankcase ventilation hose.
• 3. Connect the MAF sensor connector.

6. Fill the reservoir. The reservoir should be filled with Super DOT 4 brake fluid.

7. Bleed the clutch hydraulic system. Refer to Section 308-00 for additional information.

8. Standard finishing operations:

• Connect the ground wire to the battery.
• Enter the radio key code.
• Reprogram preset radio stations.
• Set the clock.
• Perform a road test to allow the PCM to learn the data.