Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Note: The following points are essential to ensure correct selector adjustment: Operating and transfer elements of selector mechanism must be in proper condition. Selector mechanism must move freely. The transmission, clutch and clutch mechanism must also be in proper condition. Transmission in neutral position. Carefully pry cover off from center console. Vehicles up to October 00 Remove shift knob with cover. Vehicles as of November 00 Break clamp – arrow – and pull shift knob off with cover. Continued for all vehicles The selector housing cover must be unbolted – arrows – . Measure distance between body and selector mechanism. The distance – a – must be 43 mm. If this is not the case, adjust distance – a – as follows: Loosen bolt – arrow – for push rod. The connection of push rod to selector mechanism must move freely. Set to dimension – a – by moving selector mechanism. Tighten bolt – arrow – for push rod to torque specification .

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Removal NOTE: When replacing clutch master cylinder (7A543), remove tubing from vehicle for bench bleeding procedure. 1. Disconnect the clutch master cylinder push rod from the clutch and brake pedal pivot shaft lever. 2. Disconnect the clutch pedal position switch (CPP) (11A152). 3. Remove the pushpins. 4. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the rh kick panel area. Failure to inflation of deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. For additional information, refer to Section 100-02. 5. Disconnect the clutch hydraulic line from the slave cylinder. 6. Lower the vehicle. 7. Remove the clutch master cylinder reservoir and clutch master cylinder. Rotate the clutch master cylinder 45 degrees clockwise. 8. CAUTION: Clean all rubber clutch master cylinder parts with Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Removal NOTE: When replacing clutch master cylinder (7A543), remove tubing from vehicle for bench bleeding procedure. 1. Disconnect the clutch master cylinder push rod from the clutch and brake pedal pivot shaft lever. 2. Disconnect the clutch pedal position switch (CPP) (11A152). 3. Remove the pushpins. 4. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the rh kick panel area. Failure to inflation of deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. For additional information, refer to Section 100-02. 5. Disconnect the clutch hydraulic line from the slave cylinder. 6. Lower the vehicle. 7. Remove the clutch master cylinder reservoir and clutch master cylinder. Rotate the clutch master cylinder 45 degrees clockwise. 8. CAUTION: Clean all rubber clutch master cylinder parts with Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.

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Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. Clean the area around the quick disconnect coupling. 3. Lower the vehicle. 4. Remove the two screws and the lower steering column finish panel. 5. Remove the five bolts and the lower reinforcement panel. 6. Disconnect the clutch pedal position (CPP) switch electrical connector. 7. Disconnect the clutch master cylinder rod from the clutch pedal arm. 8. Remove the CPP switch. Lift the upper cover from the lock tabs and pull the upper cover up. Rotate and remove the CPP switch from the clutch master cylinder rod. 9. Remove the reservoir. 10. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 11. Unclip the hydraulic line-to-frame retainer. 12. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Unlock and remove the clutch master cylinder assembly. Twist the clutch master cylinder counterclockwise 45 degrees to unlock it from the support bracket. 13. Remove the reservoir, the hydraulic line and the clutch master cylinder as an assembly. 14. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. To install, reverse the removal procedure. Install a new push rod retainer. Depress and release the clutch pedal 15 strokes.

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1. Raise and support the vehicle. Using the Hydraulic Line Connector Remover (308-182, T88T-70522-A), disconnect the hydraulic line from the clutch slave cylinder. See Fig. 9 . 2. Lower the vehicle. Remove the 2 screws and the lower steering column finish panel. See Fig. 10 . Remove the 5 bolts and the lower reinforcement panel. See Fig. 11 . 3. Remove the clutch master cylinder reservoir. See Fig. 16 . Remove the 3 push pins, 4 bolts, 4 screws and the inner fender splash shield. 4. Unclip the hydraulic line-to-frame retainer. Twist the clutch master cylinder clockwise 45 degrees to unlock it from the support bracket. See Fig. 17 . Remove the clutch master cylinder reservoir, the slave cylinder hydraulic line and the clutch master cylinder as an assembly. 5. Install a NEW clutch master cylinder push rod bushing. To install, reverse the removal procedure. Rotate the clutch master cylinder 45 degrees counterclockwise. Bleed the clutch hydraulic system. See BLEEDING .

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CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. Remove brake fluid spillage immediately from paint work, with clean water. 1. 2. 3. 4. 5. 6. 7. Position vehicle on a four-post lift. Move driver’s seat fully rearward. Open engine compartment and fit paint work protection covers to fenders. Disconnect battery ground cable. Remove engine compartment rear cover. Remove pedal housing, brake booster and master cylinder assembly. Remove reservoir filler cap and pour residual brake fluid into a container. Refit cap. 8. Remove the clevis pin connecting the brake pedal to the master cylinder push-rod fork. Remove grommets from access holes. Remove retaining clip. Remove clevis pin. 9. Reposition the brake pedal to access the nuts securing the brake booster to the pedal housing. Remove pivot pin nut. Remove pivot pin. Reposition brake pedal. 10. Remove brake booster from pedal housing. Remove grommet from access hole. Remove nuts.