Clutch Master Cylinder: Service and Repair

Clutch Master Cylinder Replacement

Removal Procedure

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Vehicle Damage Warnings).

1. Remove the driver side instrument panel insulator. Refer to Instrument Panel Insulator Replacement - Left Side (Left Hand Drive) (Service and Repair)Instrument Panel Insulator Replacement - Left Side (Right Hand Drive) (Instrument Panel, Gauges and Warning Indicators).
2. Disconnect the clutch pedal position switch electrical connector.




3. Disconnect the clutch master cylinder push rod (1) from the clutch pedal pin (2).




4. Remove the clutch fluid reservoir (1) from the cowl.
5. Position the clutch fluid reservoir aside.
6. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement (LHD) (Power Vacuum Brake Booster Replacement (LHD))Power Vacuum Brake Booster Replacement (RHD) (Power Vacuum Brake Booster Replacement (RHD)).

Note: Do NOT disconnect the hydraulic hoses from the clutch master cylinder.

7. Rotate the clutch master cylinder (2) clockwise 1/8 turn.
8. Remove the clutch master cylinder (2) from the cowl.
9. Remove the park brake pedal assembly from the instrument panel and position aside. Refer to Parking Brake Lever Pedal Assembly Replacement (Parking Brake Lever Pedal Assembly Replacement).





Note: Install a rubber cap over the exposed hose fitting in order to prevent fluid loss and contamination.

10. Disconnect the clutch hydraulic hose. Refer to Hydraulic Clutch Hose/Pipe Replacement (Service and Repair).

Installation Procedure




1. Connect the clutch hydraulic hose. Refer to Hydraulic Clutch Hose/Pipe Replacement (Service and Repair).




2. With the clutch fluid reservoir connection at 2 o'clock position. Insert the clutch master cylinder (2) into the cowl.
3. Align the keys of the clutch master cylinder housing with the tabs on the clutch pedal bracket.
4. Rotate the clutch master cylinder (2) counter clockwise approximately 1/8 turn until fully seated. The clutch fluid reservoir hose connection will be at vertical 12 o'clock position when the clutch master cylinder is properly installed.
5. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement (LHD) (Power Vacuum Brake Booster Replacement (LHD))Power Vacuum Brake Booster Replacement (RHD) (Power Vacuum Brake Booster Replacement (RHD)).
6. Install the clutch fluid reservoir (1) to the cowl.




7. Position the clutch master cylinder push rod (1) to the clutch pedal pin (2).
8. Push the clutch master cylinder push rod (1 onto the clutch pedal pin (2) to secure.
9. Check for proper clutch pedal movement and operation.
10. Install the driver side instrument panel insulator. Refer to Instrument Panel Insulator Replacement - Left Side (Left Hand Drive) (Service and Repair)Instrument Panel Insulator Replacement - Left Side (Right Hand Drive) (Instrument Panel, Gauges and Warning Indicators).
11. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding (Service and Repair).