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Clutch Change 2002 Fusion


Ford.fusion2002
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I have a slipping clutch on my fusion 2002 that needs the clutch replacing. I'm sure just like most clutches it's more awkward than hard to do.

The only thing I'm not sure of is the hydraulic clutch. I've only ever changed cable clutch gearboxes.

What's different with the hydro clutch?

Any how to guides anywhere?

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I have a slipping clutch on my fusion 2002 that needs the clutch replacing. I'm sure just like most clutches it's more awkward than hard to do.

The only thing I'm not sure of is the hydraulic clutch. I've only ever changed cable clutch gearboxes.

What's different with the hydro clutch?

Any how to guides anywhere?

Hydraulic clutch has two hydraulic cylinders (master & slave), one on the clutch pedal and one in the bell housing which you change when you replace the clutch. As above, there are lots of how to's on YouTube.

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Thanks, I couldn't see any fusion videos on YouTube. What's it the same as? Is it just a case of unbolting the slave and master cylinders? What do I do with the clutch fluid? Will I need to changed the fluid?

The fusion is 'basically' the same as the Fiesta, you'd need to bleed the system. You only replace the cylinder in the bellhouse. I think if you get a clutch kit it comes with the cylinder.

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Ok, how would I bleed the system is the a bleed nipple on the bell housing?

Not having done one I'll let someone else answer but you might find some info here > http://workshop-manuals.com/ford/fusion_2002.75_06.2002/mechanical_repairs/3_powertrain/308_manual_transmission-transaxle_clutch_and_transfer_case/308-02_clutch_controls/diagnosis_and_testing/removal_and_installation/clutch_master_cylinder/

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If you have experience of doing cable operated clutches you'll be fine.

Don't touch the master cylinder (fitted to the pedal) but you will have to unbolt the slave from the gearbox once the box is removed. It's a concentric slave cylinder so it is fitted around the gearbox first motion shaft. There is one hydraulic line goes into it, remove this and let the fluid drain into a suitable container. I usually let it drain for a few mins then try and put a finger from a latex glove and tape the end up to keep dirt out.

As the clutch fluid is shared with the brake fluid you will have to top this up and bleed the system. Don't be alarmed though as the clutch draws fluid from higher up in the reservoir than the brakes so you won't effect the brakes or need to bleed them.

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If it's an ib5 box then the shafts are held in with a circlip type arrangement, prying them out is usually the way. Although I find it's easier to pull the driver side shaft first then use a well placed drift right through the box and hit the passenger shaft out.

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Here are a few pics from a Focus I changed the clutch on, will probably be a similar setup to the Fusion. Might give you a little insight if your unsure.

http://www.fordownersclub.com/forums/topic/61180-focus-mk1-clutch-change-a-few-pics/?hl=%2Bfocus+%2Bclutch+%2Bchange+%2Bpics

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