Replacing the clutch release master cylinder (Fusion)

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You will need: flat- and Phillips-head screwdrivers, pliers, a 10 mm wrench, and a 13 mm socket wrench.

You will need: flat- and Phillips-head screwdrivers, pliers, a 10 mm wrench, and a 13 mm socket…


1. Remove the cap from the brake master cylinder reservoir…

1. Remove the cap from the brake master cylinder reservoir…


2. …and pump out the brake fluid from the section of the master cylinder reservoir that supplies the clutch release hydraulic drive, for example, using a large medical syringe.

Note: The reservoir, common to the brake and clutch master cylinders, consists of three separate sections: two for the separate brake hydraulic circuits and one for the clutch hydraulic circuit.


Note: The reservoir, common to the brake and clutch master cylinders, consists of three separate…


3. Remove the battery mounting shelf (see "Removal and installation the battery shelf bracket").



3. Remove the battery mounting shelf (see «Removal and installation the battery shelf bracket»).


4. Use a screwdriver to press the retainer on the tip of the supply line of the clutch release hydraulic drive and disconnect the hose from the fitting.

4. Use a screwdriver to press the retainer on the tip of the supply line of the clutch release…


5. Disconnect the clutch slave cylinder line in the same manner.

5. Disconnect the clutch slave cylinder line in the same manner.


6. Disconnect the wiring harness connector from the brake pedal position sensor and move the harness to the side.



6. Disconnect the wiring harness connector from the brake pedal position sensor and move the…


7. Using a screwdriver, pry up the retainer on the brake light switch wiring harness connector…

7. Using a screwdriver, pry up the retainer on the brake light switch wiring harness connector…


8. …disconnect the connector and move the harness to the side.

8. …disconnect the connector and move the harness to the side.


9. Remove the clutch pedal position sensor wiring harness connector retaining clip…

9. Remove the clutch pedal position sensor wiring harness connector retaining clip…


10. …disconnect the connector and move the harness to the side.



10. …disconnect the connector and move the harness to the side.


11. Squeeze the brake booster push rod fork pin retainers and remove the pin.

11. Squeeze the brake booster push rod fork pin retainers and remove the pin.


12. Unscrew the two nuts of the studs securing the pedal assembly bracket to the body (for clarity, the stud holes are shown on the removed pedal assembly)…

12. Unscrew the two nuts of the studs securing the pedal assembly bracket to the body (for clarity,…


13. …four nuts of the vacuum booster mounting studs and remove the pedal assembly from the car.



13. …four nuts of the vacuum booster mounting studs and remove the pedal assembly from the car.


14. Using pliers, separate the ends of the release spring from the pedal lever and pedal assembly bracket.

14. Using pliers, separate the ends of the release spring from the pedal lever and pedal assembly…


15. Squeezing the clutch slave cylinder pusher pin clamps..

15. Squeezing the clutch slave cylinder pusher pin clamps..


16. …remove the finger.

16. …remove the finger.


17. Remove the two bolts securing the clutch master cylinder to the pedal assembly bracket…



17. Remove the two bolts securing the clutch master cylinder to the pedal assembly bracket…


18. …pull the clutch pedal slightly…

18. …pull the clutch pedal slightly…


19. …and remove the clutch release master cylinder from the pedal assembly bracket.

20. Install the clutch release master cylinder and all previously removed parts in reverse order.






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