Tuesday, November 5, 2013

How to Install a Clutch Slave Cylinder on a 2001 Ford Super Duty

Fords 2001 Super Duty truck with a manual transmission is equipped with a hydraulic clutch system that is similar in operation to the hydraulic brake system. Pressure on the foot-operated clutch pedal actuates the clutch master cylinder and pressurizes the fluid within the system. A hydraulic hose connects the slave cylinder on the transmission to the master cylinder. When pressurized, the slave cylinder disengages the clutch plates. Over time, the inner seals in the slave cylinder can become worn and cease to function properly. Replace the slave cylinder using basic hand tools.

Instructions

Removal

    1

    Park the vehicle on level ground. Set the parking brake. Chock the rear wheels.

    2

    Position the jack under the front lifting points on the vehicle. The two-wheel drive truck has a lifting lug located on the front side of the wheel support arm. Jack the four-wheel truck on the front axle close to the wheel. Be sure to position the jack in the notch near the front differential when lifting the driver side of four-wheel drive trucks. Support the vehicle on jack stands.

    3

    Locate the slave cylinder on the front driver side of the transmission. Wipe dirt from the slave cylinder, hydraulic hose and surrounding areas with a clean rag to prevent contamination of the components. Place a catch pan under the clutch slave cylinder.

    4

    Push in on the slave cylinder and rotate it counterclockwise to remove it from the transmission. Pull the hydraulic hose clip closest to the slave cylinder from the truck body.

    5

    Drive out the roll pin on the slave cylinder hydraulic hose coupling, using a hammer and a 3/32 inch punch. Discard the roll pin.

    6

    Disconnect the clutch hydraulic tube from the slave cylinder. Remove the O-ring seal from the end of the hydraulic tube and discard.

Installation

    7

    Hold the new clutch slave cylinder over the catch pan. Position the slave cylinder so that the hydraulic connection port is higher than the pushrod. Fill the slave cylinder with DOT 3 brake fluid.

    8

    Install the new O-ring seal on the end of the hydraulic line and coat it with fresh DOT 3 brake fluid. Insert the hydraulic line into the slave cylinder hydraulic port. Install a new roll pin using a hammer to secure the hydraulic line in the slave cylinder.

    9

    Locate the clutch master cylinder reservoir next to the brake master cylinder on the drivers side of the engine compartment firewall.

    10

    Wipe the clutch master cylinder cap with a clean rag to remove any grit or debris. Remove the clutch master cylinder cap. Fill the clutch master cylinder with fresh DOT 3 brake fluid up to the Full line. Position the clutch hydraulic hose so that there are no high spots that may trap air bubbles during the bleeding process. Reroute the hose as necessary.

    11

    Hold the slave cylinder vertically with the pushrod down and the hydraulic line lined up with the hydraulic line as straight as possible to the clutch master cylinder.

    12

    Slowly push the pushrod into the slave cylinder until it bottoms out and then hold it for five to ten seconds. Release the pushrod slowly and allow the spring within the slave cylinder to extend the pushrod. Wait five to 10 seconds to allow the air bubbles to rise. Repeat this process until all of the air is bled from the system and the clutch master cylinder is free of air bubbles.

    13

    Insert the slave cylinder into the transmission housing. Push the slave cylinder in and rotate it clockwise until it snaps into position. Push the hydraulic line clip into position on the truck body.

    14

    Remove the jack stands and lower the vehicle.

    15

    Slowly depress and release the clutch pedal 25 times. Ensure that the fluid in the clutch master cylinder is free of air bubbles.

    16

    Check and top off the fluid level in the clutch master cylinder. Install the master cylinder cap.

    17

    Remove the jack stands and lower the truck to the ground.


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