MT285/MTX75 Transaxles

Clutch Master Cylinder

Removal

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush the eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

1. Disconnect the battery ground cable.

2. CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.

CAUTION: The brake fluid reservoir cap must not become contaminated.

Using a suitable syringe, remove brake fluid from the brake fluid reservoir until the brake fluid level is at the MIN mark.
- Install the brake fluid reservoir cap.
3. Remove the air cleaner.





4. Detach the Central Junction Box (CJB) from the mounting bracket.
1 Remove the retaining bolt.
2 Release the clip.





5. CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.

NOTE: Cap the clutch master cylinder and slave cylinder fluid supply lines to prevent fluid loss or dirt ingress.

Using a suitable thin bladed screwdriver disconnect the clutch master cylinder and slave cylinder fluid supply lines.
- Remove the clips.





6. Detach the instrument panel lower pane] from the instrument panel.
1 Remove the screws.
2 Release the fastener.





7. Remove the instrument panel lower panel.
- Detach the Data Link Connector (DLC).
- Disconnect the hood release cable.





8. Detach the clutch slave cylinder supply line from the front bulkhead.
- Remove the clip.





9. Remove the brake pedal actuating rod retaining pin.
- Depress the locking tang.
10. Disconnect the starter safety switch, clutch position switch, speed control deactivation switch and stop lamp switch electrical connectors from the pedal assembly.





11. Remove the switches from the pedal assembly.
1 Speed control deactivation switch (colored green).
2 Stop lamp switch (colored grey).
3 Clutch position switch (colored red).
4 Starter safety switch (colored black).





12. NOTE: The complete pedal assembly must be removed to gain access to the clutch master cylinder retaining bolts.

Remove the pedal assembly.





13. Remove the clutch master cylinder.
- Mount the pedal assembly in a suitable vise.
- Remove the retaining bolts.
- Detach the clutch master cylinder from the pedal assembly and slide the actuating rod off the pedal arm.

Installation





1. Install the clutch master cylinder.
- Attach the actuating rod to the pedal arm.
- Attach the clutch master cylinder to the pedal assembly.
2. Position the pedal assembly in the vehicle.





3. CAUTION: Make sure the brake pedal actuating rod retaining pin is locked in position. When correctly installed, the locking tab on the side of the retaining pin will be visible as it extends through the actuating rod and the brake pedal.

CAUTION: Push and pull the retaining pin to make sure it is correctly installed.

Install the brake pedal actuating rod retaining pin.





4. install the pedal assembly retaining nuts.





5. Attach the clutch slave cylinder supply the to the front bulkhead.
- Install the clip.





6. NOTE: The clutch position switch (colored red) is not adjustable.

Pull out the starter safety switch, speed control deactivation switch and stop lamp switch plungers until they are fully extended.
- Measure the plunger length.
- Speed control deactivation switch (colored green) XX mm = 24 mm.
- Stop lamp switch (colored grey) XX mm = 21 mm.
- Starter safety switch (colored black) XX mm = 26 mm.





7. CAUTION: When installing the switches, the stop lamp switch is rotated to the counterclockwise and the remaining switches are rotated to the clockwise. Failure to follow this instruction will result in the switch plungers binding inside the switch.

CAUTION: Make sure the switches are correctly installed.

NOTE: The speed control deactivation switch and the stop lamp switch are automatically adjusted during installation.

NOTE: A slight ratcheting noise and feel during installation of the speed control deactivation switch and the stop lamp switch is normal.

Install the switches to the pedal assembly.
1 Speed control deactivation switch (colored green).
2 Stop lamp switch (colored grey).
3 Clutch position switch (colored red).
4 Starter safety switch (colored black).

8. NOTE: The colors of the electrical connectors and the switches are identical.

Connect the electrical connectors to the pedal assembly switches.

9. NOTE: A slight ratcheting noise and feel during switch adjustment is normal.

Adjust the starter safety switch (colored black) by pressing and then releasing the clutch pedal.





10. NOTE: Install new O-ring seals if necessary.

Connect the clutch master cylinder and slave cylinder fluid supply lines to the clutch master cylinder.
- Insert the clips.





11. Connect the hood release cable and the Data Link Connector (DLC) to the instrument panel lower panel.





12. Attach the instrument panel lower panel trim to the instrument panel.
1 Secure the fastener.
2 Install the screws.





13. Attach the Central Junction Box (CJB) to the mounting bracket.
1 Install the retaining bolt.
2 Attach the clip.
14. Install the air cleaner.
15. Top up the brake fluid reservoir with Super DOT 3 brake fluid.
16. Bleed the hydraulic clutch system.
17. Connect the battery ground cable.