Clutch Master Cylinder: Service and Repair

REMOVAL

NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required.





1. Remove air cleaner assembly (Fig. 16).
2. Disconnect battery negative cable.
3. Raise vehicle on hoist.








4. Using Tool 6638A, disconnect clutch hydraulic quick-connect (Fig. 18) (Fig. 17).





5. Remove hydraulic hose from left rail retainer (Fig. 21).
6. Lower vehicle.
7. Remove PDC bracket and position out of way.





8. Remove lower instrument panel bezel (Fig. 19).





9. Remove clip and disconnect the brake booster input rod from the brake pedal pin (Fig. 20).
10. Remove the brake booster mounting nuts (Fig. 20).
11. Slide brake booster forward enough to gain access to and remove clutch master cylinder.
12. Remove clutch master cylinder reservoir (Fig. 21).
13. Disconnect clutch master cylinder rod from clutch pedal. Inspect plastic retainer. If retainer is broken or damaged in any way, it MUST be replaced upon reassembly.
14. Remove two clutch master cylinder retaining nuts.
15. Remove the bulkhead connector bracket.

CAUTION: Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly.

16. Remove master cylinder from mounting position and carefully work hydraulic pipe from out of engine compartment (Fig. 21). If necessary, unfasten ABS module and purge solenoid assembly to gain necessary clearance.

INSTALLATION
1. Install the master cylinder into position on the dash panel.
2. Install the bulkhead connector bracket.
3. Install the master cylinder retaining nuts onto the master cylinder studs. Tighten the nuts to 34 Nm (300 inch lbs.).
4. Route the hydraulic tube as noted upon removal.
5. Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line.
6. Install the master cylinder remote reservoir onto the dash panel.
7. Install the reservoir retaining screws. Tighten the screws to 3 Nm (24 inch lbs.).
8. Install the brake booster.

CAUTION: Inspect the clutch master cylinder push rod plastic retainer for damage. If it is damaged (broken/cracked), it MUST be replaced.

9. Install the push rod onto the pedal pin.





10. Loosen the push rod adjustment screw (Fig. 22) and gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 8 Nm (70 inch lbs.).
11. Install the ABS module/purge solenoid, PDC, and air cleaner.
12. Depress and release the clutch pedal a minimum of ten (10) times to allow any residual air in the system to be vented to the reservoir.
13. Connect the negative battery cable.
14. Verify correct clutch operation.