Clutch Master Cylinder: Service and Repair

Part 1 Of 2:

Part 2 Of 2:

REMOVAL
1. REMOVE LUGGAGE COMPARTMENT TRIM BOX COVER

2. DISCONNECT CLUTCH LINE FROM CLUTCH MASTER CYLINDER
Using SST, disconnect the clutch line.
SST 09023-38200

HINT: Use a container to catch the fluid.

3. REMOVE CLIP AND PIN
4. REMOVE CLUTCH MASTER CYLINDER
a. Using needle-nose pliers, remove the clip and pin.

b. Remove the 2 nuts.
c. Pull out the master cylinder.

DISASSEMBLY
1. REMOVE RESERVOIR

a. Using a pin punch and a hammer, tap out the slotted spring pin.
b. Remove the reservoir.
c. Remove the grommet from the reservoir.
d. Remove the cap and float from the reservoir.
2. REMOVE CLEVIS
Loosen the lock nut, and remove the clevis and lock nut.
3. REMOVE PUSH ROD

a. Remove the boot.
b. Using snap ring pliers, remove the snap ring while pushing the push rod.
c. Pull out the push rod and washer.
4. REMOVE PISTON WITH SPRING

REASSEMBLY

1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN
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.
c. Using snap ring pliers, install the snap ring.
4. INSTALL BOOT TO CYLINDER
5. TEMPORARILY INSTALL LOCK NUT AND CLEVIS
6. INSTALL RESERVOIR
a. Install the float and cap to the reservoir.
b. Install a new grommet and reservoir to the cylinder body.

c. Using a pin punch and a hammer, tap in the slotted spring pin.

INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER

a. Install the master cylinder with the 2 nuts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b. Connect the push rod to the clutch pedal with the pin and pin clip.

2. CONNECT CLUTCH LINE
Using SST, connect the clutch line.
SST 0902-38200
Torque:
20 Nm (204 kgf-cm, 15 ft. lbs.)
18 Nm (185 kgf-cm, 13 ft. lbs.) for use with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).

3. FILL RESERVOIR AND BLEED CLUTCH SYSTEM AND ADJUST CLUTCH PEDAL
4. CHECK FOR LEAKS
5. INSTALL LUGGAGE COMPARTMENT TRIM BOX COVER