Clutch Master Cylinder: Service and Repair

REMOVAL
1. REMOVE BRAKE BOOSTER





2. DISCONNECT RESERVOIR HOSE
a. Using pliers, disconnect the clip.
b. Disconnect the reservoir hose from the inlet union.
c. Use a container to catch the fluid.





3. DISCONNECT CLUTCH LINE
a. Using SST, disconnect the clutch line.
SST 09023-00100
b. Use a container to catch the fluid.
4. REMOVE CLIP AND PIN
Using needle-nose pliers, remove the clip and pin.
5. REMOVE 2 MOUNTING NUTS AND PULL OUT MASTER CYLINDER

DISASSEMBLY





1. REMOVE INLET UNION
a. Using a pin punch (3 mm) and hammer, drive out the slotted spring pin.
b. Remove the inlet union.
c. Remove the grommet.
2. REMOVE CLEVIS
Loosen the lock nut to remove the clevis and remove the lock nut.
3. REMOVE BOOT FROM CYLINDER





4. REMOVE PUSH ROD
a. While pushing the push rod, using snap ring pliers, remove the snap ring.
b. Pull out the push rod and washer.
5. REMOVE PISTON WITH SPRING FROM CYLINDER

REASSEMBLY





1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN IN ILLUSTRATION
2. INSERT PISTON WITH SPRING INTO CYLINDER





3. INSTALL PUSH ROD
a. Install the washer to the push rod.
b. Push the push rod into the piston, using snap ring pliers, install the snap ring.
4. INSTALL BOOT TO CYLINDER
5. TEMPORARILY INSTALL LOCK NUT AND CLEVIS





6. INSTALL INLET UNION
a. Install a new grommet.
b. Install the inlet union.
c. Using a pin punch (3 mm) and hammer, drive in the slotted spring pin.

INSTALLATION
1. INSTALL MASTER CYLINDER WITH 2 MOUNTING NUTS
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
2. INSTALL PIN AND CLIP





3. CONNECT CLUTCH LINE
Using SST, connect the clutch line.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





4. CONNECT RESERVOIR HOSE
a. Connect the reservoir hose to the inlet union.

NOTICE: Facing the yellow mark upwards.

b. Using pliers, connect the clip.
5. INSTALL BRAKE BOOSTER
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM
7. ADJUST CLUTCH PEDAL
8. CHECK FOR LEAKS