Clutch Master Cylinder: Service and Repair

REMOVAL

1. Drain the clutch fluid through the bleed plug (A).

2. Remove clevis pin (A), split pin (cotter pin) (C) and washer (B).

3. Disconnect the clutch tube (A) (master cylinder side).

4. Remove the master cylinder mounting nuts (A) and clutch reservoir mounting bolts (B).
5. Remove the clutch line clips (A).

6. Hold the nut on the clutch hose (B) and loosen the flare nut (C) on the clutch tube.
7. Remove the clutch tube.

8. Disconnect the clutch hose (A) (release cylinder side).

INSPECTION
Check the rust, pitting and scoring of the clutch hose.

INSTALLATION

1. Connect the clutch tube (A) (release cylinder side).

2. Temporarily tighten the flare nut by hand, then tighten it to the specified torque, being careful that the clutch hose does not become twisted.

3. Install the clutch tube and clips (A).

4. Install the master cylinder (A).

5. Apply the specified grease to the clevis pin and washer.
6. Install the push rod to the clutch pedal.
7. Pour the clutch fluid into the clutch master cylinder.
8. Bleed the clutch system.

DISASSEMBLY
1. Remove the piston stop ring.
2. Pull out the push rod and piston assembly.

3. Remove the reservoir band, reservoir cap, and reservoir.

INSPECTION
1. Check the inside of the cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check the clutch tube line for clogged.

5. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.
6. If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly.
Limit: 0.15 mm (0.006 inch)

REASSEMBLY
1. Apply the specified fluid to the inner surface of the master cylinder body (A) and to the entire periphery of the piston assembly (B).
Specified fluid: Brake fluid DOT 3 or DOT 4
2. Install the piston assembly.
3. Install the piston snap ring.

4. Install the push rod assembly.