Clutch Master Cylinder: Service and Repair

CLUTCH MASTER CYLINDER (2.7L/T850 MODELS)

REMOVAL
1. Open hood.
2. Disconnect battery negative cable at strut tower.
3. Remove fuse box access cover.
4. Remove instrument panel lower close-out panel.
5. Disconnect clutch master cylinder pushrod from clutch pedal pin.
6. Remove air cleaner assembly.
7. Remove clutch master cylinder reservoir from speed control servo bracket.
8. Lift purge solenoid off of mounting bracket and secure out of way.
9. Disconnect speed control servo connector. Remove speed control servo/bracket from strut tower and secure out of way.
10. Raise vehicle on hoist.
11. Using tool 6638, disconnect clutch hydraulic circuit quick-connect fitting.
12. Lower vehicle.
13. Rotate master cylinder 1/4 turn counter-clockwise and remove from dash panel/clutch pedal bracket.
14. Work master cylinder and plumbing out of engine compartment, using care not to bend or damage plumbing. Note routing of plumbing for reassembly.

INSTALLATION
1. Install master cylinder and plumbing into position as removed. Use care not to bend or damage plumbing.
2. Install master cylinder pushrod through dash panel hole. Index master cylinder 1/4 turn counterclockwise, then apply pressure towards dash panel and rotate 1/4 turn clockwise. If necessary, have helper guide installation from inside vehicle.
3. Connect master cylinder pushrod to clutch pedal pin. An audible click should be heard. Verify plastic retainer is intact and secures pushrod. If retainer is damaged, it MUST be replaced.
4. Install instrument panel lower close-out panel.
5. Install fuse box access panel.
6. Raise vehicle.
7. Route master cylinder plumbing into position and connect to slave cylinder. An audible click should be heard. Verify by pulling outward on connection.
8. Lower vehicle.
9. Install purge solenoid to mounting bracket.
10. Connect brake master cylinder level sensor connector.
11. Install speed control servo and connect connector.
12. Install clutch master cylinder reservoir.
13. Install air cleaner assembly.
14. Install battery negative cable.
15. Verify clutch pedal operation. Actuate clutch pedal at least ten times to purge any trapped air from system.
16. Check and adjust clutch master cylinder fluid level.