Clutch Master Cylinder: Service and Repair

CLUTCH MASTER CYLINDER ASSEMBLY (MTM)
OVERHAUL
1. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
2. REMOVE BRAKE ACTUATOR ASSEMBLY
3. REMOVE BRAKE BOOSTER ASSEMBLY
4. REMOVE CLUTCH PEDAL SPRING





5. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/ HOLE PIN
a. Remove the clip and the hole pin.
6. DRAIN CLUTCH FLUID

NOTICE: Immediately wash off any brake fluid that comes in contact with a painted surface.






7. REMOVE CLUTCH RESERVOIR TUBE
a. Loosen the clip and remove the clutch reservoir tube from the clutch master cylinder assembly.





8. 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.

9. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY
a. Remove the 2 nuts and clutch master cylinder assembly.





10. 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 the grommet.
c. Loosen the lock nut, and remove the push rod clevis.
d. Remove the lock nut from the push rod.
e. Remove the boot from the cylinder body.





f. While pushing the push rod, remove the snap ring using snap ring pliers.
g. Remove the push rod from the cylinder body.

NOTICE: The piston may pop 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 spring from the cylinder.

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

11. INSTALL CLUTCH MASTER CYLINDER KIT





a. Coat the parts with lithium soap base glycol grease, as shown in the illustration.
b. install the piston with 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. While pushing the push rod, install the snap ring using snap ring pliers.
f. Install the boot on the cylinder body.
G. Install the lock nut on the push rod.
h. Temporarily install the push rod clevis with the lock nut on 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.
12. 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.)





13. 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.)





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

NOTICE:
^ Connect the clutch reservoir tube, taking care not to twist it.
^ Face the white mark upward.





15. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/ HOLE PIN
a. Apply MP grease to the contact surface of the hole pin and the clevis bush.
b. Connect the clevis to the clutch pedal 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.
16. INSTALL CLUTCH PEDAL SPRING
17. INSTALL BRAKE BOOSTER ASSEMBLY
18. INSTALL BRAKE ACTUATOR ASSEMBLY
19. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
20. BLEED CLUTCH PIPE LINE
a. Fill the brake reservoir tank with clutch fluid and bleed clutch system.
Torque: 8.4 Nm (86 kgf-cm, 74 in. lbs.)
21. CHECK CLUTCH FLUID LEAKAGE

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

22. CHECK FLUID LEVEL IN RESERVOIR
23. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY