Clutch Master Cylinder: Service and Repair
CLUTCH MASTER CYLINDERCOMPONENTS:
REMOVAL
1. DRAIN CLUTCH FLUID
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.
HINT: Use a container to catch the fluid.
SST 09023-00101
6. REMOVE CLUTCH PEDAL SPRING (WITHOUT TURN OVER)
7. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH HOLE PIN
(a) Remove the clip and hole pin.
8. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY
(a) Remove the 2 nuts and clutch master cylinder assembly.
DISASSEMBLY
1. 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) While pushing the push rod, using snap ring pliers, remove the snap ring.
(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.
NOTICE: Be careful not to damage the inside of the cylinder body.
REASSEMBLY
1. INSTALL CLUTCH MASTER CYLINDER KIT
(a) Coat 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, using snap ring pliers, install the snap ring.
(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.
INSTALLATION
1. 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.)
2. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH 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.
3. INSTALL CLUTCH PEDAL SPRING (WITHOUT TURN OVER)
4. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using SST, connect the flexible hose tube.
Torque: 15 Nm (155 kgf/cm, 11 ft. lbs.)
SST 09023-00101
5. CONNECT CLUTCH RESERVOIR TUBE
(a) Connect the clutch reservoir tube with the clip to the clutch master cylinder assembly.
NOTICE: Facing the white mark upward.
6. INSTALL BRAKE BOOSTER ASSEMBLY
7. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
8. BLEED BRAKE LINE
9. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with clutch fluid and bleed clutch system.
Torque: 8.4 Nm (85 kgf/cm, 74 in. lbs.)
10. INSPECT AND ADJUST BRAKE PEDAL HEIGHT
11. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY
12. INSPECT FOR BRAKE FLUID LEAK
13. INSPECT FOR CLUTCH FLUID LEAK
14. CHECK FLUID LEVEL IN RESERVOIR