Ford Fiesta's

For anyone who has not changed them...

If your BMI is on the wrong side of 36 - 24 - 36 then these jobs are not for you.

OK so its a back-breaking job and better left to the younger techs...

To remove it...

Using a pick release the two clips securing the two pipes into the clutch master cylinder under the bonnet after removing the air box. Turn the deliver tube upside down to stop loss of fluid from the brake master cylinder. use rags underside the clutch master cylinder pipe which leads off to the clutch slave cylinder. 

Working inside the car (upside down) 

Remove the clutch pedal using a 14 mm and a 13 mm ratchet spanners. The pedal has a strong return spring on it which connects to the clutch master cylinder body. It will fall off and the bush's and sleeves will fall out the pedal on removal.

The clutch master cylinder is held to a plate welded to the bulkhead by two 10 mm headed screws. Remove them and the cylinder with a bit of help will pull out of the bulkhead, with a little twisting here and there. 

So far so good...

Insert the clutch pedal return spring into the guide hole on the new clutch master cylinder. Don't try to locate the opposite end of the spring on the clutch pedal.

Locate and fit the new clutch master cylinder into the bulkhead wall and ensure that the clutch master cylinder correctly locates in the bulkhead mounting bracket correctly. There are two plastic guides integral with the clutch master cylinder, ensure they are located through the mounting bracket and slide into the correct position. Refit the two 10 mm headed screws. (This can be a real problem if you get this wrong, read on)

Now put the guide bushes and pin back into the clutch pedal pivot. Locate the return spring correctly around the top of the clutch pedal in the groove provided.

Now the tricky bit...

Push the clutch pedal upwards into the pedal box and make sure that you don't break off the plunger for the clutch pedal switch while pushing upwards against the return spring. Guide the bolt back through the pedal box to locate and secure the clutch pedal. Tighten the bolt.

Now the reason for the post...

If you try to or do fit the pedal into the pedal box and locate the bolt first, then you will be fighting against the return spring tension force trying to pull down, locate and twist the master cylinder body into the mounting bracket. You will swear and call Ford not fit to burn until you realize like me that you are assembling the clutch pedal assembly the wrong way round. 

Prime the hydraulics and job done.