Repair Procedures

REMOVAL

1. Disconnect the clutch tube(A).




2. Remove the clutch release cylinder mounting bolt.

INSTALLATION

1. Coat the clevis push rod specified grease.

Specified grease: CASMOLY L9508




2. Install the release cylinder(A) to the transaxle.

TORQUE :
15 - 22Nm (150 - 220 kgf.cm, 11 - 16 lb-ft)




3. Install the clutch tube(A).






INSPECTION

1. Check the release cylinder bore for rust and damage.
2. Measure the release cylinder bore at three locations (bottom, middle, and top) with a cylinder gauge and replace the release cylinder assembly if the bore-to-piston clearance exceeds the limit.

Limit clearance to piston: 0.15 mm (0.006 in.)




3. Check the clutch release cylinder for fluid leakage.
4. Check the clutch release cylinder boots for damage.

DISASSEMBLY

1. Remove the clutch hose, valve plate, spring, push rod, and boot.
2. Remove any dirt from the piston bore opening of the release cylinder.
3. Remove the piston from the release cylinder using compressed air.

CAUTION:
- Use rags to prevent the piston from popping out and causing injury.
- Apply compressed air slowly. Keep the fluid from splashing in your eyes or on your skin.





REASSEMBLY

1. Apply specified brake fluid to the release cylinder bore and the outer surface of the piston and piston cup, and push the piston cup assembly into the cylinder.

Specified fluid: Brake fluid DOT 3 or DOT 4

2. Install the valve plate(A), Spring(B), push rod(C) and boot(D).