Clutch Hydraulic System Service

IMPORTANT: The clutch hydraulic system is to be serviced as a COMPLETE UNIT!!!. It is a sealed unit and has been filled with fluid and bled of air at the factory. Individual components of the system are not available for service, except the slave cylinder actuator pushrod plastic retainer strap. Do not attempt to bleed the clutch hydraulic system. The bleed screw located on the clutch hydraulic slave cylinder is used for the factory fluid fill only.


WARNING: Do not attempt to bleed the clutch hydraulic unit. Any observed fittings are there for factory use only. The unit comes as a complete pre-bled unit.




REMOVAL





1. Block clutch pedal up to prevent pedal from being depressed with slave cylinder removed from transaxle.





2. Remove air induction system.





3. Disconnect negative battery cable from battery.
4. Disconnect positive battery cable from battery
5. Remove hold-down retaining nut and screw, and lift off battery hold-down retainer.
6. Lift the battery of vehicle, and place in a safe location.





7. Remove battery tray bolts and tray.

IMPORTANT: One bolt is located in the fender well.





NOTICE: Removal of the hydraulic damper with a power tool prior to removal of the actuator could result in breaking off the hydraulic line.

IMPORTANT: Prior to removing the slave cylinder from the clutch housing, make sure that the clutch hydraulic system has sufficient fluid. Refer to the "Clutch Hydraulic Fluid Check" procedures in this manual. (This is not necessary if the clutch hydraulic system is being removed to be replaced.)

8. Rotate actuator 1/4 turn counterclockwise while pushing toward housing in order to disengage the bayonet connector and remove from clutch housing.
9. Remove two hydraulic damper to clutch housing nuts and slide damper and bracket assembly off studs.





10. ABS equipped vehicles, remove brake master cylinder-to-booster nuts.

NOTICE: ABS equipped vehicles require the brake master cylinder to be moved off booster studs and moved slightly towards the engine to allow removal of the clutch hydraulic master cylinder. Use care not to bend or kink brake lines.





11. Remove clutch master cylinder pushrod retainer clip from clutch pedal pin and disconnect pushrod from pedal.
12. Turn clutch master cylinder approximately 1/8 turn clockwise and remove from dash.
13. Remove hydraulic system from vehicle.

INSTALLATION

IMPORTANT: When installing a new unit, the plastic retainer straps on the actuator remain in place when installing the unit. This will ensure the actuator rod is seated in the clutch release fork pocket as the actuator is installed.

IMPORTANT: When installing an existing unit, a new plastic retainer strap should be installed on the end of the pushrod and the straps should be attached to the actuator.





1. Install clutch master cylinder into dash with reservoir leaning outboard. Turn approximately 1/8 turn counterclockwise to lock in position.
2. On ABS equipped vehicles, place the brake master cylinder back on the booster studs and tighten brake master cylinder-to-booster nuts.
- Torque: 27 N.m (20 ft. lbs.).





3. Slide damper and bracket onto clutch housing damper studs and install nuts.
- Torque: 25 N.m (18 ft. lbs.).
4. Install actuator into clutch housing with hydraulic line facing down and rotate actuator 1/4 turn clockwise while pushing toward housing.
5. Add dielectric (silicone) grease to clutch pedal pin then connect pushrod and install pushrod retainer clip to clutch pedal pin.





6. Install battery tray.
7. Torque battery tray bolts.
- Torque: 10 N.m (89 inch lbs.).





8. Make sure battery tray is clean.
9. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
10. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
11. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
12. Install battery hold-down retainer, locking the battery into the tray. Install and tighten the hold-down retainer nut and screw.
- Torque: 9 N.m (80 inch lbs.).
13. Install the positive battery cable first.
- Torque: 17 N.m (151 inch lbs.).
14. Install the negative battery cable last.
- Torque: 17 N.m (151 inch lbs.).





15. Install air induction system.
- Torque: 10 N.m (89 inch lbs.).