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Tuesday, November 8, 2011

How to replace master cylinder for 2003 ford focus


Master Cylinder


Bench Bleeding Procedure




NOTE
Ford recommends bleeding the master cylinder in the vehicle with a pressure pump.


CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hand thoroughly after handling. If brake fluid contacts the eyes, flush the eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.


WARNING
If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

  1. Remove the brake fluid reservoir cap.
  2. The reservoir fluid level should be at the MIN mark.
  3. Connect the reservoir hose to the clutch slave cylinder bleed nipple.
  4. Loosen the clutch slave cylinder bleed nipple.
  5. Pump approximately 80 ml of the brake fluid into the clutch system with a suitable fluid pump.
  6. Tighten the clutch slave cylinder bleed nipple to 89 inch lbs. (10 Nm)
  7. Remove the special tool.
  8. Install the clutch slave cylinder bleed nipple dust cap.
  9. Check the fluid level in the brake fluid reservoir and top up as necessary with Super DOT 4 brake fluid.
  10. Install the brake fluid reservoir cap.

    Click image to see an enlarged view
    Fig. Injecting fluid into the clutch master cylinder through the bleed screw.

Removal & Installation




CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush the eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    WARNING
    If brake fluid is spilled on the paintwork the affected area must be immediately washed down with cold water.
  3. Using a suitable syringe, remove brake fluid from the brake fluid reservoir until the brake fluid level is at the MIN mark.
  4. Install the brake fluid reservoir cap.
  5. Remove the air cleaner.
  6. Detach the central junction box (CJB) from the mounting bracket.
    NOTE
    Cap the clutch master cylinder and slave cylinder fluid supply lines to prevent fluid loss or dirt ingress.
  7. Using a suitable thin bladed screwdriver disconnect the clutch master cylinder and slave cylinder fluid supply lines.
  8. Detach the instrument panel lower panel from the instrument panel.
  9. Detach the data link connector (DLC).
  10. Disconnect the hood release cable.
  11. Detach the clutch slave cylinder supply line from the front bulkhead.
  12. Remove the brake pedal actuating rod retaining pin.
  13. Disconnect the starter safety switch, clutch position switch, speed control deactivation switch and stop lamp switch electrical connectors from the pedal assembly.
  14. Remove the switches from the pedal assembly.
    NOTE
    The complete pedal assembly must be removed to gain access to the clutch master cylinder retaining bolts.


    WARNING
    Remove the pedal assembly.
  15. Remove the clutch master cylinder.
To install:
  1. Install the clutch master cylinder.
  2. Position the pedal assembly in the vehicle.
    NOTE
    Make sure the brake pedal actuating rod retaining pin is locked in position. When correctly installed, the locking tab on the side of the retaining pin will be visible as it extends through the actuating rod and the brake pedal.
  3. Install the pedal assembly retaining nuts.
  4. Attach the clutch slave cylinder supply line to the front bulkhead.
    NOTE
    The clutch position switch (colored red) is not adjustable.
  5. Pull out the starter safety switch, speed control deactivation switch and stop lamp switch plungers until they are fully extended.
    WARNING
    When installing the switches, the stop lamp switch is rotated to the counterclockwise and the remaining switches are rotated to the clockwise. Failure to follow this instruction will result in the switch plungers binding inside the switch.


    NOTE
    The speed control deactivation switch and the stop lamp switch are automatically adjusted during installation.


    NOTE
    A slight ratcheting noise and feel during installation of the speed control deactivation switch and the stop lamp switch is normal.
  6. Install the switches to the pedal assembly.

    Speed control deactivation switch (colored green).
    Stop lamp switch (colored grey).
    Clutch position switch (colored red).
    Starter safety switch (colored black).
  7. Connect the electrical connectors to the pedal assembly switches.
  8. Adjust the starter safety switch (colored black) by pressing and then releasing the clutch pedal and install new O-ring seals if necessary.
  9. Connect the clutch master cylinder and slave cylinder fluid supply lines to the clutch master cylinder.
  10. Connect the hood release cable and the data link connector (DLC) to the instrument panel lower panel.
  11. Attach the instrument panel lower panel trim to the instrument panel and secure the fastener.
  12. Attach the central junction box (CJB) to the mounting bracket and securely tighten the retaining bolt.
  13. Install the air cleaner.
  14. Top up the brake fluid reservoir with Super DOT 3 brake fluid.
  15. Bleed the hydraulic clutch system.

CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush the eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    WARNING
    If brake fluid is spilled on the paintwork the affected area must be immediately washed down with cold water.
  3. Using a suitable syringe, remove brake fluid from the brake fluid reservoir until the brake fluid level is at the MIN mark.
  4. Install the brake fluid reservoir cap.
  5. Remove the air cleaner.
  6. Detach the central junction box (CJB) from the mounting bracket.
    NOTE
    Cap the clutch master cylinder and slave cylinder fluid supply lines to prevent fluid loss or dirt ingress.
  7. Disconnect the clutch master cylinder and slave cylinder fluid supply lines.
  8. Detach the instrument panel lower panel from the instrument panel.
  9. Detach the data link connector (DLC).
  10. Disconnect the hood release cable.
  11. Detach the clutch slave cylinder supply line from the front bulkhead.
  12. Remove the brake pedal actuating rod retaining pin.
  13. Disconnect the starter safety switch, clutch position switch, speed control deactivation switch and stop lamp switch electrical connectors from the pedal assembly.
  14. Remove the switches from the pedal assembly.
    NOTE
    The complete pedal assembly must be removed to gain access to the clutch master cylinder retaining bolts.


    WARNING
    Remove the pedal assembly.
  15. Remove the clutch master cylinder.
To install:
  1. Install the clutch master cylinder.
  2. Position the pedal assembly in the vehicle.
    NOTE
    Make sure the brake pedal actuating rod retaining pin is locked in position. When correctly installed, the locking tab on the side of the retaining pin will be visible as it extends through the actuating rod and the brake pedal.
  3. Install the pedal assembly retaining nuts.
  4. Attach the clutch slave cylinder supply line to the front bulkhead.
    NOTE
    The clutch position switch (colored red) is not adjustable.
  5. Pull out the starter safety switch, speed control deactivation switch and stop lamp switch plungers until they are fully extended.
    WARNING
    When installing the switches, the stop lamp switch is rotated to the counterclockwise and the remaining switches are rotated to the clockwise. Failure to follow this instruction will result in the switch plungers binding inside the switch.


    NOTE
    The speed control deactivation switch and the stop lamp switch are automatically adjusted during installation.


    NOTE
    A slight ratcheting noise and feel during installation of the speed control deactivation switch and the stop lamp switch is normal.
  6. Install the switches to the pedal assembly.

    Speed control deactivation switch (colored green).
    Stop lamp switch (colored grey).
    Clutch position switch (colored red).
    Starter safety switch (colored black).
  7. Connect the electrical connectors to the pedal assembly switches.
  8. Adjust the starter safety switch (colored black) by pressing and then releasing the clutch pedal and install new O-ring seals if necessary.
  9. Connect the clutch master cylinder and slave cylinder fluid supply lines to the clutch master cylinder.
  10. Connect the hood release cable and the data link connector (DLC) to the instrument panel lower panel.
  11. Attach the instrument panel lower panel trim to the instrument panel and secure the fastener.
  12. Attach the central junction box (CJB) to the mounting bracket and securely tighten the retaining bolt.
  13. Install the air cleaner.
  14. Top up the brake fluid reservoir with Super DOT 3 brake fluid.
  15. Bleed the hydraulic clutch system.
---------------------------------
For more car related problem troubleshooting:---

This are the sections, you can go through and click the link to read its troubleshooting.

---------

The car will not start?

http://schematicsdiagram.blogspot.com/2011/06/car-will-not-start.html
-----------------

Car will not crank?

http://schematicsdiagram.blogspot.com/2011/06/car-will-not-crank.html

-----------

Car has no spark?

http://schematicsdiagram.blogspot.com/2011/06/car-has-no-spark.html

-------------

How to troubleshoot car battery?

http://schematicsdiagram.blogspot.com/2011/06/how-to-troubleshoot-car-battery.html
-----------------

How to test starter solenoid?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-starter-solenoid.html

--------------------

How to test cars starter?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-cars-starter.html

How to replace starter in car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-starter-in-car.html


-----------

car will turn over but will not start?


http://technoanswers.blogspot.com/2011/05/car-will-turn-over-but-will-not-start.html

-----------------

Car wont start?

http://howtobyme.blogspot.com/2011/10/car-wont-start.html

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Posted by Hemant somaiya at 9:53 PM
Labels: auto parts, Brake fluid, car problem, clutch slave cylinder, ford focus problem, how to, install master cylinder, procedure of bench bleeding, replace master cylinder, reservoir, vehicle

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