Clutch Master Cylinder: Service and Repair

Clutch Master Cylinder Replacement

NOTE:

- Use fender covers to avoid damaging painted surfaces.
- Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or plastic, wash it off immediately with water.
- Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

1. Remove and discard the brake fluid from the clutch reservoir with a syringe or other suitable device.

2. Do the battery removal procedure Removal and Replacement.

3. Remove the air cleaner Service and Repair.

4. Remove the battery base.

5. Pry out the lock pin (A), and pull the clevis pin (B) out of the clevis. Remove the master cylinder mounting nuts (C).






6. Remove the clutch reservoir mounting bolt (A).





7. Remove the clutch line bracket (B).

8. Remove the clutch master cylinder (C).

9. Disconnect the reservoir hose (A), then remove the retaining clip (B) and the clutch line (C) from the clutch master cylinder (D). Plug or wrap the end of the reservoir hose and the clutch line with a clean shop towel to prevent brake fluid from coming out.





10. Remove the O-ring (E) and the clutch master cylinder seal (F) from the clutch master cylinder.

11. Install a new O-ring (A) on the clutch line (B).

NOTE: Apply silicone grease (P/N 08C30- B0234M) to the O-ring and the end of the clutch line.





12. Install the clutch line in the clutch master cylinder (C) with a new retaining clip (D). Connect the reservoir hose (E).

13. To prevent the retaining clip (A) from coming off, pry apart the tip (B) of the clip with a screwdriver.






14. Install the clutch master cylinder (A) with a new clutch master cylinder seal (B).





15. Install the clutch line bracket (C).

16. Install the clutch reservoir mounting bolt (D).

17. Make sure the hose clamps (A) are positioned on the clutch master cylinder (B) and the clutch reservoir (C) as shown.






18. Install the master cylinder mounting nuts (A).





19. Apply multipurpose grease to the clevis pin (B), and slide it into the clevis, then install the lock pin (C).

20. Bleed the clutch hydraulic system Service and Repair.

21. Adjust the clutch pedal, the clutch pedal position switch, and the clutch interlock switch Adjustments.

22. Install the air cleaner Service and Repair.

23. Install the battery base.

24. Do the battery installation procedure Removal and Replacement.

25. Check the clutch operation and check for leaks.

26. Test-drive the vehicle.