Clutch Master Cylinder: Service and Repair

Clutch Master Cylinder Replacement

Tools Required
^ J36221 Hydraulic Clutch Line Separator

Removal Procedure
1. Disable the supplemental inflatable restraints (SIR) system. Refer to Restraint Disabling and Enabling Zone 3.
2. Remove the left instrument panel (I/P) lower insulator panel.





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





4. Remove the clutch master cylinder reservoir retaining bolt (1).
5. Position the clutch master cylinder out of the way.
6. Remove the brake booster assembly from the vehicle.
7. Disconnect the hydraulic pipe from the clutch master cylinder.
8. Cap the hydraulic pipe to prevent contamination to the system.
9. Remove the clutch master cylinder retaining nuts.
10. Remove the clutch master cylinder and reservoir from the vehicle.

Installation Procedure





1. Install the clutch master cylinder and gasket into the opening in front of the dash.

2. Notice:
Refer to Fastener Notice in Service Precautions.

Install the clutch master cylinder retaining nuts (3).

Tighten the clutch master cylinder nuts (3) to 25 Nm (18 ft. lbs.).

3. Connect the hydraulic pipe to the clutch master cylinder.

Tighten the clutch master cylinder hydraulic pipe to 10 Nm (7 ft. lbs.).

4. Install the brake vacuum booster.





5. Install the clutch master cylinder fluid reservoir and bolt (1) to the brake master cylinder.

Tighten the bolt to 10 Nm (7 ft. lbs.).

6. Check the clutch hydraulic reservoir hose for twists or kinks.





7. Important:
Ensure the quick connect retaining clips are fully engaged in the groove (1).

Install the clutch master push rod (1) to the clutch pedal pivot pin.
8. Install the left driver side instrument panel insulator.
9. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.