How to Install a Clutch Slave Cylinder on a 1996 Ford Truck F-150

The Ford Motor Company equipped their 1996 year model F-150 manual transmissions with a hydraulic clutch control system. Depressing the clutch lever inside the vehicle operates the clutch master cylinder. Pressurized hydraulic fluid travels through the clutch line to the clutch slave cylinder. Clutch engagement decreases as the slave cylinder expands and pushes against the throwout bearing. Wear and contaminated fluid cause the slave cylinder to weaken and fail. As a rule, change slave cylinders and master cylinders as a set.

Things You'll Need

• Brake fluid
• 12-point socket set
• 3/8-inch ratchet handle
• 3/8-inch torque wrench

Instructions

1. Rotate the cylinder until the inlet port is the highest point of the cylinder. Pour fluid into the cylinder to fill it up. Rock the cylinder and gently operate the clutch pushrod to expel all the air out of the cylinder to prime it.

2. Slide the slave cylinder onto the transmission input shaft. Orient the cylinder with the line coupling and bleed screw pointing toward the right side of the transmission (looking from the front of the transmission).

3. Install the 12-point mounting bolts through the slave cylinder flange and into the transmission with a ratchet and 12-point socket. Torque the mounting bolts to between 14 and 19 foot-pounds using a 12-point socket and 3/8-inch torque wrench.

4. Connect the hydraulic line coupling. Slide the male fitting into the female fitting and push them together securely. Tug slightly on the line to ensure a secure connection.

Tips & Warnings

• Ford hydraulic clutch systems use brake fluid. Do not add transmission fluid to this system or severe damage will occur to the rubber components in the system.

References

• "Ford Pick-Ups and Bronco, 1980 thru 1996 (Haynes Repair Manual)"; Mark Christman, John B. Raffa and John H. Haynes; 1996

Resources

• Cornell University, Kinematic Models for Design Digital Library: Multiple Disk Clutch