To remove the master cylinder, first disconnect the negative battery cable. Inside the vehicle, move the driver's seat fully to the rear to create maximum working space, then remove the fasteners securing the driver's side lower dash trim panel and take the panel out, unclipping the diagnostic connector plug as you do so. Although optional, removing the clutch pedal can simplify the process. Prepare for potential spillage of hydraulic brake fluid by placing clean rags below the clutch pedal and having a container ready in the engine compartment. On later models, unbolt and set aside the underhood electrical junction block to access the fluid connections at the firewall. Use a suction device to extract as much fluid as possible from the reservoir, then remove the brake fluid reservoir cap and reseal it with cellophane or cling film to minimize spillage when disconnecting the lines. To access the fluid connections at the engine compartment firewall, jack up the front of the car and support it on axle stands. In the engine compartment or from below, remove the securing clip from the top of the larger fluid supply connection and pull the pipe fitting from the master cylinder, plugging or clamping the hose end to prevent fluid loss. For the smaller fluid pressure pipe, release it from the support bracket, remove the securing clip, and pull the pipe fitting out of the base of the cylinder, again plugging or taping the end. Back in the driver's footwell, unscrew the nut or remove the metal clip securing the pipe flange to the firewall, then take out the two bolts that secure the master cylinder body to the pedal bracket. For 2005 and later models, it is recommended to remove the entire clutch/brake pedal assembly. Unclip the master cylinder from the pedal bracket and carefully pry off the piston rod from the top of the clutch pedal, taking care not to tilt the master cylinder to avoid further fluid spillage. For installation, reverse the removal steps, ensuring to tighten the mounting bolts to the specified torque, install new clips if needed when reconnecting the fluid pipes, and reinstall the clutch pedal if it was removed. Remove the cellophane from under the fluid reservoir cap and top up the fluid level, then bleed the clutch hydraulic system. If the fluid level in the reservoir dropped significantly, it may also be necessary to bleed the brake system. After completing the installation, operate the clutch a few times without starting the engine and check for fluid leakage at the firewall connections in the engine compartment. Finally, start the engine and verify correct clutch operation.
Posted by FordPartsGiant Specialist 
