Ford Ranger/Explorer/Mountaineer 1991-1999

Master Cylinder and Reservoir

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The hydraulic clutch system operates much like a hydraulic brake system. When you push down (disengage) the clutch pedal, the mechanical clutch pedal movement is converted into hydraulic fluid movement, which is then converted back into mechanical movement by the slave cylinder to actuate the clutch release lever.

The system consists of a combination clutch fluid reservoir/master cylinder assembly, a slave cylinder mounted on the bellhousing, and connecting tubing.

Fluid level is checked at the master cylinder reservoir. The hydraulic clutch system continually remains in adjustment, like a hydraulic disc brake system, so not clutch linkage or pedal adjustment is necessary.

REMOVAL & INSTALLATION



See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Typical hydraulic clutch system used on all models

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  4.  
  5. Remove the switch from the master cylinder assembly, if equipped.
  6.  
  7. Remove the screw retaining the fluid reservoir to the cowl access cover.
  8.  
  9. Disconnect the tube from the slave cylinder and plug both openings.
  10.  
  11. Remove the bolts retaining the clutch master cylinder to the dash panel and remove the clutch master cylinder assembly.
  12.  

To install:
  1. Install the pushrod through the hole in the engine compartment. Make certain it is located on the correct side of the clutch pedal. Place the master cylinder assembly in position and install the retaining bolts. Tighten to 1-12 ft. lbs. (11-16Nm).
  2.  
  3. Insert the coupling end into the slave cylinder and install the tube into the clips.
  4.  
  5. Fit the reservoir on the cowl access cover and install the retaining screws.
  6.  
  7. Replace the retainer bushing in the clutch master cylinder pushrod if worn or damaged. Install the retainer and pushrod on the clutch pedal pin. Make certain the bushing is fitted correctly with the flange of the bushing against the pedal blade.
  8.  
  9. Install the switch.
  10.  
  11. Bleed the system.
  12.  
  13. Reconnect the negative battery cable.
  14.  

 
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