Clutch Master Cylinder: Service and Repair

CLUTCH MASTER CYLINDER ASSEMBLY (MTM)
OVERHAUL
1. DRAIN CLUTCH FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

2. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
3. REMOVE BRAKE BOOSTER ASSEMBLY





4. DISCONNECT CLUTCH RESERVOIR TUBE
a. Loosen the clip and disconnect the clutch reservoir tube from the clutch master cylinder assembly.

HINT: Use a container to catch the fluid.





5. DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
a. Using SST, disconnect the flexible hose tube.
SST 09023-00101

HINT: Use a container to catch the fluid.





6. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
a. Remove the clip and hole pin.
7. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY
a. Remove the 2 nuts and clutch master cylinder assembly.





8. REMOVE CLUTCH MASTER CYLINDER KIT
a. Using a pin punch and a hammer, drive out the slotted spring pin.
b. Remove the inlet union and grommet.
c. Loosen the lock nut, and remove the clevis.
d. Remove the lock nut from the push rod.
e. Remove the boot from the cylinder body.





f. Using snap ring pliers, remove the snap ring while pushing on the piston rod.
g. Remove the push rod from the cylinder body.

NOTICE: The piston may pop up out of the cylinder body. Therefore, slowly remove the push rod from the cylinder body.

h. Remove the stop plate from the push rod.
i. Remove the piston with the spring from the cylinder.

NOTICE: Be careful not to damage the inside of the cylinder body.

9. INSTALL CLUTCH MASTER CYLINDER KIT





a. Coat the parts indicated by arrows with lithium soap base glycol grease.
b. Install the piston with the spring into the cylinder.

NOTICE: Be careful not to damage the inside of the cylinder body.

c. Install the stop plate to the push rod.
d. Install the push rod to the cylinder body.





e. Using snap ring pliers, install the snap ring while pushing on the piston rod.
f. Install the boot to the cylinder body.
g. Install the lock nut to the push rod.
h. Temporarily install the clevis with the lock nut to the push rod.
i. Install the inlet union and a new grommet.





j. Using a pin punch and a hammer, drive in the slotted spring pin.
Protrusion: 1.5 to 3.5 mm (0.059 to 0.138 inch)
10. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY
a. Install the clutch master cylinder assembly with the 2 nuts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





11. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
a. Apply MP grease to the contact surface of the hole pin and clevis bush.
b. Connect the clevis to the clutch pedal sub-assembly with the hole pin.

HINT: Install the hole pin from the right side of the vehicle.

c. Install the clip to the hole pin.





12. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
a. Using SST, connect the flexible hose tube.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





13. CONNECT CLUTCH RESERVOIR TUBE
a. Connect the clutch reservoir tube with the clip to the clutch master cylinder assembly.

NOTICE: Face the red mark upward.

14. INSTALL BRAKE BOOSTER ASSEMBLY
15. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
16. BLEED BRAKE LINE
17. BLEED CLUTCH PIPE LINE
a. Fill the brake reservoir tank with clutch fluid and bleed the clutch system.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
18. CHECK AND ADJUST BRAKE PEDAL HEIGHT
19. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY
20. BLEED BRAKE LINE
21. CHECK FOR BRAKE FLUID LEAKAGE

HINT:
- Check for leakage in the brake system.
- Check for leakage in the clutch system.

22. CHECK FLUID LEVEL IN RESERVOIR