Clutch Master Cylinder: Service and Repair

REMOVAL AND INSTALLATION
REMOVAL

IMPORTANT: The clutch master and actuator cylinder assembly is to be serviced as a complete unit. It is a sealed unit and has been filled with fluid and bled of air at the factory. Individual components of the system are not available for service, except the slave cylinder actuator pushrod plastic retainer strap.





1. Block clutch pedal up to prevent pedal from being depressed with slave cylinder removed from transaxle.





2. Remove air cleaner and duct assembly.





3. Disconnect negative battery cable from battery.
4. Disconnect positive battery cable from battery
5. Remove hold-down retaining nut and screws, and lift off battery hold-down retainer.
6. Lift battery out of vehicle, and place in a safe location.





7. Disconnect PCM J2 (black 28-way) harness connector by moving locking device outward toward fender.

NOTICE: The PCM J1 (black 80-way) harness connector does not need to be disconnected.

8. Remove PCM attachment bolts and move PCM out of way.

IMPORTANT: One bolt is located in the fender well.

9. Remove battery tray bolts and tray.

NOTICE: Removal of the hydraulic damper with a power tool prior to removal of the actuator could result in breaking off the hydraulic line.

IMPORTANT: Prior to removing the slave cylinder from the clutch housing, make sure that the clutch hydraulic system has sufficient fluid. Refer to the "Clutch Hydraulic Fluid Check" procedures. (This is not necessary if the clutch hydraulic system is being removed to be replaced.)





10. Rotate actuator 1/4 turn counterclockwise while pushing toward housing in order to disengage the bayonet connector and remove from clutch housing.
11. Remove two hydraulic damper to clutch housing nuts and slide damper and bracket assembly off studs.

NOTICE: Brake master cylinder does not need to be moved to gain access to clutch master cylinder assembly.





12. Remove ABS control assembly.





13. Remove clutch master cylinder pushrod retainer clip from clutch pedal pin and disconnect pushrod from pedal.

NOTICE: Use care not to bend or kink brake lines.

14. Turn clutch master cylinder approximately 1/8 turn clockwise and remove from dash.
15. Remove clutch master and actuator assembly from vehicle.

INSTALLATION

IMPORTANT: When installing a new unit, leave the clutch slave cylinder pushrod retainer in place when installing the unit. This will ensure the actuator rod is seated in the clutch release fork pocket as the actuator is installed.

IMPORTANT: When installing an existing unit, a new clutch slave cylinder pushrod retainer should be installed on the end of the pushrod and the straps should be attached to the actuator.





1. Install clutch master cylinder into dash with reservoir leaning outboard. Turn approximately 1/8 turn counterclockwise to lock in position.
2. On ABS equipped vehicles, place the brake master cylinder back on the booster studs and tighten brake master cylinder-to-booster nuts.
- Torque: 27 Nm (20 ft. lbs.)
3. Slide damper and bracket onto clutch housing damper studs and install nuts.
- Torque: 25 Nm (18 ft. lbs.)





4. Install actuator into clutch housing with hydraulic line facing down and rotate actuator 1/4 turn clockwise while pushing toward housing.
5. Add dielectric (silicone) grease to clutch pedal pin then connect pushrod and install pushrod retainer clip to clutch pedal pin.

NOTICE: ABS system must be bled. Refer to the "ABS Control Assembly Installation" procedure in Brakes and Traction Control."





6. Install ABS control assembly. Refer to the "ABS Control Assembly Installation" procedure in Brakes and Traction Control."





7. Install battery tray.
8. Torque battery tray bolts.
- Torque: 10 Nm (89 inch lbs.)
9. Install PCM and PCM attachment bolts.
- Torque: 6 Nm (53 inch lbs.)
10. Reconnect PCM J2 (black 28-way) harness connector and secure locking device.





11. Make sure battery tray is clean.
12. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
13. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
14. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
15. Install battery hold-down retainer (3), locking the battery into the tray. Install and tighten the hold-down retainer (1) nut and screws (2).
- Torque: 9 Nm (80 inch lbs.)
16. Install the positive battery cable first.
- Torque: 17 Nm (13 ft. lbs.)
17. Install the negative battery cable last.
- Torque: 17 Nm (13 ft. lbs.)





18. Install air cleaner and duct assembly.
- Torque: 10 Nm (89 inch lbs.)