Clutch Master Cylinder: Service and Repair

Clutch Master Cylinder Replacement

Removal Procedure

1. Disable the SIR system. Refer to SIR Disabling and Enabling (Service and Repair).
Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
3. Remove the clutch pedal assembly. Refer to Clutch Pedal Replacement (Service and Repair).
4. Place the clutch pedal on a suitable work surface.





Note: Note the position of the clutch over centre spring (4).

5. Remove the clutch over centre spring (4).
6. Use a suitable screwdriver to pry off the push rod connector (1).
7. Disconnect the push rod connector (1) from the clutch pedal.
8. Remove the clutch master cylinder to clutch pedal retaining bolts (3).
9. Remove the clutch master cylinder (2).

Installation Procedure




1. Install the clutch master cylinder (2) to the pedal assembly (1).

Note: The clutch master cylinder to clutch pedal retaining bolts (1) must not to be fully tightened at this stage.

2. Install the clutch master cylinder to clutch pedal retaining bolts (1).
Do not fully tighten at this stage.
3. Connect the push rod connector (3) to the clutch pedal pin (4).
4. Remove the clutch position switch.

Note: Measure from pedal pad bottom edge when at the top of travel to mod plate surface plane.

5. With an assistant raise clutch pedal to a height of 224 mm (a) to achieve the correct pedal height.

Caution: Refer to Fastener Caution (Fastener Caution).

6. Tighten the clutch master cylinder to clutch pedal retaining bolts (1) and tighten to 12 Nm (106 lb in).





Note: Pushing the pedal to the bottom of travel will assist with the clutch over centre spring (1) installation.

Note: Make sure that the clutch over centre spring (1) is installed in its original position.

7. Install the clutch over centre spring (1).
8. Install the clutch position switch.
9. Install the clutch pedal assembly. Refer to Clutch Pedal Replacement (Service and Repair).
10. Reconnect the clutch patch harness to the cockpit harness.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
12. Enable the SIR system. Refer to SIR Disabling and Enabling (Service and Repair).
13. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding (Service and Repair).
14. Road test vehicle for correct clutch operation.