Clutch: Service and Repair

LINKAGE / REMOVAL

CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected.

1. Raise and support vehicle.





2. Remove nuts attaching slave cylinder to studs on clutch housing (Fig. 12).
3. Remove slave cylinder from clutch housing.
4. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange.
5. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud.
6. Lower vehicle.





7. Disconnect clutch pedal interlock switch wires (Fig. 13).
8. Remove clutch master cylinder rod pin.
9. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal.
10. Remove clutch master cylinder nuts holding the to the dash panel.
11. Remove clutch cylinders, reservoir and connecting lines from vehicle.

INSTALLATION
1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring.
2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye.
3. Install clutch master cylinder on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.).
4. Install clutch master cylinder push rod pin.
5. Connect clutch pedal position interlock switch wires.
6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange.
7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud.
8. Raise vehicle.
9. Install slave cylinder and verify cylinder rod is properly seated in release lever.
10. Install and tighten slave cylinder nuts to 23 Nm (17 ft. lbs.).
11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder.

CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected.

12. Lower vehicle.
13. Operate linkage several times to verify proper operation.