Clutch Master Cylinder: Service and Repair

Fig. 2 Clutch Master Cylinder Replacement:

Fig. 3 Exploded View Of Clutch Master Cylinder:

REMOVAL
1. Disconnect battery ground cable.
2. Remove hush panel from passenger compartment, then disconnect pushrod from clutch pedal.
3. Disconnect slave cylinder hydraulic line from master cylinder.
4. Remove master cylinder retaining nuts and the master cylinder, Fig. 2.

DISASSEMBLY
1. Remove reservoir and seal from master cylinder.
2. Remove rubber dust cover from cylinder, Fig. 3.
3. Remove snap ring and pushrod, then shake out plunger and spring assembly.
4. Remove reservoir adapter and seal, as required.
5. Remove spring, seal support, recuperation seal and shim from plunger.

INSPECTION
1. Replace seals and clean all components in clean brake fluid.
2. Inspect cylinder bore for visible scores and ridges. Ensure it is smooth to the touch. Replace master cylinder if defective.

ASSEMBLY
1. Apply clean brake fluid to seals and cylinder bore. Install back seal, shim, recuperation seal, seal support and spring on plunger.
2. Carefully slide plunger assembly into master cylinder bore.
3. Position pushrod into plunger, then depress plunger and install snap ring.
4. Apply suitable grease to inside of rubber dust cover, then install the dust cover.
5. Install reservoir adapter seal, then press in the adapter.

INSTALLATION
1. Install master cylinder assembly and tighten retaining nuts to specifications.
2. Connect pushrod to clutch pedal and install retaining clip.
3. Install hush panel, then connect slave cylinder hydraulic line to master cylinder.
4. Fill master cylinder reservoir with new brake fluid, then bleed system as described under MAINTENANCE PROCEDURES/CLUTCH SYSTEM BLEED.
5. Connect battery ground cable.