Left Hand Drive
MASTER CYLINDER-LHDREMOVAL - T350 Models
NOTE: These models are equipped with a one-piece master/slave cylinder assembly. If the master cylinder requires replacement, the master AND slave cylinder must be replaced with a two-piece "quick-connect" system. If the slave cylinder requires replacement, the slave cylinder is serviced separately.
NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the slave cylinder assembly.
1. Remove air cleaner assembly (Fig. 28).
2. Disconnect battery negative cable.
3. Raise vehicle on hoist.
4. Remove slave cylinder from transaxle (Fig. 29).
5. Remove hydraulic hose from left rail retainers (Fig. 32).
6. Lower vehicle.
7. Remove PDC bracket and position out of way.
8. Remove lower instrument panel bezel (Fig. 30).
9. Remove clip and disconnect the brake booster input rod from the brake pedal pin (Fig. 31).
10. Remove the brake booster mounting nuts (Fig. 31).
11. Slide brake booster forward enough to gain access to and remove clutch master cylinder.
12. Remove clutch master cylinder reservoir (Fig. 32).
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 self-docking 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. 32). If necessary, unfasten ABS module and purge solenoid assembly to gain necessary clearance. If difficulty is encountered in removing system from vehicle, cut master cylinder hydraulic tube to divide system into two pieces.
INSTALLATION - T350 MODELS
NOTE: These models are equipped with a one-piece master/slave cylinder assembly. If the master cylinder requires replacement, the master AND slave cylinder must be replaced with a two-piece "quick-connect" system. If the slave cylinder requires replacement, the slave cylinder is serviced separately.
1. Install the master cylinder into position on the dash panel. Route the hydraulic tube underhood as noted upon removal.
2. Install the self-docking connector bracket.
3. Install the master cylinder retaining nuts onto the master cylinder studs. Tighten the nuts to 11 Nm (100 inch lbs.).
4. Install the master cylinder remote reservoir onto the dash panel.
5. Install the reservoir retaining screws. Tighten the screws to 11 Nm (103 inch lbs.).
6. 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.
7. Raise vehicle on hoist.
8. If master cylinder is being replaced, install service replacement slave cylinder. If master cylinder is being re-used, install slave cylinder as shown in (Fig. 29).
9. If master cylinder is being replaced, connect the master cylinder hydraulic line to the service replacement slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line.
10. Lower vehicle.
11. Loosen the push rod adjustment screw (Fig. 37).
12. Install the push rod onto the pedal pin.
13. Gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 6 Nm (55 inch lbs.).
14. Install the ABS module/purge solenoid, PDC, and air cleaner.
15. 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.
16. Connect the negative battery cable.
17. Top off clutch master cylinder reservoir with DOT 3 brake fluid.
18. Verify correct clutch operation.