Master Cylinder - RDH
MASTER CYLINDER / REMOVAL - RHDNOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required.
1. Disconnect battery negative cable.
2. Raise vehicle on hoist.
3. Using Tool 6638A, disconnect clutch hydraulic quick-connect (Fig. 36) and (Fig. 37).
4. Remove hydraulic hose (Fig. 38) from the clips along the frame rail and the dash panel.
5. Lower vehicle.
6. Remove the two screws holding the master cylinder remote reservoir to the dash panel.
7. Disconnect the master cylinder push rod from the pedal pin. Inspect plastic retainer. If retainer is damaged in any way, it MUST be replaced.
8. Remove the clutch interlock/upstop switch cover plate and switch housing (Fig. 39) from the master cylinder push rod.
9. From the engine compartment, grasp the master cylinder body and rotate approximately 45° in a counter-clockwise direction.
10. Disengage the master cylinder from the pedal bracket assembly.
11. Remove the master cylinder from the vehicle.
INSTALLATION - RHD
1. Install the master cylinder into position on the dash panel. (Fig. 41)
2. Seat the master cylinder in the pedal bracket assembly.
3. Rotate the master cylinder approximately 45° in the clockwise direction.
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 clutch interlock/upstop switch and cover plate. (Fig. 42)
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. 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. If residual air becomes trapped in the system, bleed the clutch hydraulic system.
11. Connect the negative battery cable.
12. Top off clutch master cylinder reservoir with DOT 3 brake fluid.
13. Verify proper clutch operation.