Clutch Master Cylinder: Service and Repair

A: REMOVAL
1. Thoroughly drain brake fluid from reservoir tank.





2. Remove snap pin, clevis pin and separate push rod of master cylinder from clutch pedal.
3. Remove clutch pipe from master cylinder.





4. Remove master cylinder with reservoir tank.

CAUTION: Be extremely careful not to spill brake fluid. Brake fluid spilt on the vehicle body will harm the paint surface; wipe it off quickly if spilt.

B: DISASSEMBLY





1. Remove straight pin and reservoir tank.





2. Remove oil seal.





3. Move the cylinder boot backward.
4. Remove snap ring.

CAUTION: Be careful when removing the snap ring to prevent the rod, washer, piston and return spring from flying out.





5. Remove damper cylinder from master cylinder body.

C: INSPECTION





If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, return spring and gasket, replace the faulty part.

D: ASSEMBLY

CAUTION:
Apply a coat of grease to the contacting surfaces of the push rod and piston before installation.

1. To assemble the master cylinder reverse the sequence of disassembly procedure.
2. Install damper cylinder washer. Install damper cylinder and tighten to the specified torque.

Tightening torque: T: 46.6 ± 7.4 Nm (4.75 ± 0.75 kg-m, 34.4 ± 5.4 ft. lbs.)

E: INSTALLATION





1. Install master cylinder to body, and install clutch pipe to master cylinder.

CAUTION: Check that pipe is routed properly.

Tightening torque:
T: 18 ± 3 Nm (1.8 ± 0.3 kg-m, 13.0 ± 2.2 ft. lbs.)





2. Connect push rod of master cylinder to clutch pedal, and install clevis pin and snap pin.

NOTE: Apply grease to clevis pin.

3. After bleeding air from system, ensure that clutch operates properly.