Clutch Master Cylinder: Service and Repair
CLUTCH MASTER CYLINDERCOMPONENTS:
REMOVAL
1. DRAIN BRAKE FLUID
NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.
2. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY
a. Remove the master cylinder.
3. REMOVE BRAKE BOOSTER ASSEMBLY
a. Remove the booster.
4. DISCONNECT CLUTCH RESERVOIR TUBE
a. Loosen the clip and disconnect the clutch reservoir tube from the clutch master cylinder.
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 HOLE PIN
a. Remove the clip and hole pin.
7. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY
a. Remove the 2 nuts and clutch master cylinder.
DISASSEMBLY
1. REMOVE CLUTCH MASTER CYLINDER KIT
a. Using a pin punch and hammer, tap 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 and push rod.
i. Remove the piston with the spring from the cylinder.
NOTICE: Be careful not to damage the inside of the cylinder body.
REASSEMBLY
1. 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 hammer, tap in the slotted spring pin.
Standard protrusion: 1.5 to 3.5 mm (0.059 to 0.138 inch)
INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY
a. Install the clutch master cylinder with the 2 nuts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
2. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS 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 with the hole pin.
HINT: Install the hole pin from the right side of the vehicle.
c. Install the clip to the hole pin.
3. 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.)
4. CONNECT CLUTCH RESERVOIR TUBE
a. Connect the clutch reservoir tube to the clutch master cylinder with the clip.
NOTICE: Face the red mark upward.
5. INSTALL BRAKE BOOSTER ASSEMBLY
a. Install the booster.
6. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY
a. Install the master cylinder.
7. BLEED AIR FROM BRAKE LINE
a. Bleed the air from brake line.
8. BLEED AIR FROM CLUTCH PIPE LINE
a. Fill the brake reservoir with brake fluid and bleed air from the clutch system.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
9. CHECK AND ADJUST BRAKE PEDAL HEIGHT
10. INSPECT AND ADJUST CLUTCH PEDAL SUBASSEMBLY
11. BLEED AIR FROM BRAKE LINE
12. CHECK FOR BRAKE FLUID LEAKAGE
HINT:
^ Check for leakage in the brake system.
^ Check for leakage in the clutch system.
13. CHECK FLUID LEVEL IN RESERVOIR