Clutch Master Cylinder: Service and Repair
CLUTCH MASTER CYLINDERCOMPONENTS:
REMOVAL
1. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
2. REMOVE BRAKE ACTUATOR ASSEMBLY
3. REMOVE BRAKE BOOSTER ASSEMBLY
4. REMOVE CLUTCH PEDAL SPRING
5. DISCONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
a) Remove the clip and pin and disconnect the push rod clevis from the clutch pedal.
6. DRAIN BRAKE FLUID
NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.
7. DISCONNECT CLUTCH RESERVOIR TUBE
a) Loosen the clip and disconnect the tube from the clutch master cylinder.
HINT: Use a container to catch the fluid.
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.
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 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 with snap ring pliers.
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 spring from the cylinder body.
NOTICE: Be careful not to damage the inside of the cylinder body.
REASSEMBLY
1. INSTALL CLUTCH MASTER CYLINDER KIT
a) Coat the parts shown in the illustration with lithium soap base glycol grease.
b) Install the piston with spring into the cylinder body.
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 with 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 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: 9.0 Nm (80 kgf-cm, 81 inch lbs.)
2. 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.)
3. CONNECT CLUTCH RESERVOIR TUBE
a) Connect the clutch reservoir tube to the clutch master cylinder with the clip.
NOTICE:
^ Connect the clutch reservoir tube so that it will not be twisted.
^ Face the white mark upward.
4. CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
a) Apply MP grease to the contact surface of the pin and clevis bush.
b) Connect the clevis to the clutch pedal with the pin and clip.
HINT: Install the pin from the left side of the vehicle.
c) Install the clip to the pin.
5. INSTALL CLUTCH PEDAL SPRING
6. INSTALL BRAKE BOOSTER ASSEMBLY
7. INSTALL BRAKE ACTUATOR ASSEMBLY
8. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
9. BLEED CLUTCH PIPE LINE
a) Fill the brake reservoir with brake fluid and bleed the clutch system.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
10. CHECK BRAKE FLUID
HINT:
^ Check for leakage in the brake system.
^ Check for leakage in the clutch system.
11. CHECK FLUID LEVEL IN RESERVOIR
12. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY