Clutch Master Cylinder: Service and Repair

Clutch Master Cylinder Replacement

NOTE:

- Use fender covers to avoid damaging painted surfaces.

- Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or plastic, wash it off immediately with water.

1. Remove the brake fluid from the clutch master cylinder reservoir with a syringe or other suitable device.

2. Do the battery removal procedure. Removal and Replacement

3. Remove the driver's dashboard undercover. Driver's Dashboard Undercover Removal/Installation

4. Remove the air cleaner housing; 5-speed manual transmission, Service and Repair 6-speed manual transmission. Service and Repair

5. Remove the battery base; 5-speed manual transmission Manual Transmission Removal, 6-speed manual transmission. Manual Transmission Removal

6. Pry out the lock pin (A), and pull the clevis pin (B) out of the clevis. Remove the master cylinder mounting nuts (C).

7. Remove the cowl cover and the under-cowl panel. Service and Repair






8. Remove the clutch line bracket (A).

9. Remove the clutch line from the clamps (B).






10. Remove the clutch master cylinder (A) with the clutch line (B) and the reservoir hose (C).






11. Remove the reservoir hose (A), then remove the retaining clip (B) for disconnecting the clutch line (C) from the clutch master cylinder (D). Plug or wrap the end of the reservoir hose and the clutch line with a shop towel to prevent brake fluid from coming out.
NOTE: Inspect the hose. If the hose has damage, leaks interference, or twisting, replace it.

12. Remove the O-ring (E) and the clutch master cylinder seal (F) from the clutch master cylinder.






13. Install a new O-ring (A) on the clutch line (B), then install the clutch line in the clutch master cylinder (C) with a new retaining clip (D).
NOTE:

- Apply the silicone grease (P/N 08C30-B0234M) on the O-ring and the end (E) of the clutch line.

- Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

14. Install the reservoir hose (F).






15. Make sure the hose clamps (A) are positioned on the master cylinder (B) and the reservoir (C) as shown.






16. To prevent the retaining clip (A) from coming off, pry apart the tip (B) of the clip with a screwdriver.






17. Install the clutch master cylinder (A) with a new clutch master cylinder seal (B).






18. Install the clutch line to the clamps (A).

19. Install the clutch line bracket (B).

20. Install the cowl cover and the under-cowl panel. Service and Repair






21. Install the master cylinder mounting nuts (A).

22. Apply multipurpose grease to the clevis pin (B) and the mating surface of the clevis and the pedal. Slide the clevis pin into the clevis, then install the lock pin (C).

23. Do the clutch hydraulic system bleeding. Service and Repair

24. Adjust the clutch pedal, the clutch pedal position switch, and the clutch interlock switch. Adjustments

25. Install the battery base; 5-speed manual transmission, Manual Transmission Installation 6-speed manual transmission. Manual Transmission Installation

26. Install the air cleaner assembly; 5-speed manual transmission Service and Repair, 6-speed manual transmission. Service and Repair

27. Install the driver's dashboard undercover. Driver's Dashboard Undercover Removal/Installation

28. Do the battery installation procedure. Removal and Replacement

29. Check the clutch operation, and check for leaks.

30. Test-drive the vehicle.