Clutch Master Cylinder

Clutch Master Cylinder





Material

Removal

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush the eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

CAUTION: If brake fluid is spilled on the paint, the affected area must be immediately washed down with cold water.

1. Disconnect the battery ground cable.





2. CAUTION: The brake fluid reservoir cap must not become contaminated.

Using a suitable tool, remove brake fluid from the brake fluid reservoir until the brake fluid level is at the MIN mark.
^ Install the brake fluid reservoir cap.
3. Remove the air cleaner.





4. Detach the Central Junction Box (CJB) from the mounting bracket.
1. Remove the retaining bolt.
2. Release the clip.





5. NOTE: Cap the clutch master cylinder and slave cylinder fluid supply lines to prevent fluid loss.

Remove the clips, then disconnect the clutch master cylinder and slave cylinder fluid supply lines.





6. Remove the instrument panel lower panel from the instrument panel.
1. Remove the screws.
2. Release the fastener.





7. Remove the instrument panel lower panel.
^ Detach the Data Link Connector.
^ Disconnect the hood release cable.





8. Remove the clip, then disconnect the clutch slave cylinder supply line from the front bulkhead.





9. Depress the locking tang and remove the brake pedal actuating rod retaining pin.
10. Disconnect the starter safety switch, clutch position switch, speed control deactivation switch and brake lamp switch electrical connectors from the pedal assembly.





11. Remove the switches from the pedal assembly.
1. Speed control deactivation switch (green).
2. Stop lamp switch (prey).
3. Clutch position switch (red).
4. Starter safety switch (black).





12. NOTE: The complete clutch pedal assembly and the clutch master cylinder must be removed to gain access to the clutch master cylinder bolts.

Remove the clutch pedal assembly nuts and the pedal assembly.





13. Separate the clutch master cylinder from the clutch pedal.
^ Mount the pedal assembly in a suitable vise. Remove the clutch master cylinder bolts. Detach the clutch master cylinder from the pedal assembly and slide the actuating rod from the pedal arm.

Installation





1. Attach the clutch master cylinder to the clutch pedal assembly.
^ Attach the actuating rod to the pedal arm. Install the clutch master cylinder bolts.
2. Position the clutch pedal assembly in the vehicle.





3. CAUTION: Make sure the brake pedal actuating rod retaining pin is locked in position. When correctly installed, the locking tab on the side of the retaining pin will be visible as it extends through the actuating rod and the brake pedal.

CAUTION: Push and pull the retaining pin to make sure it is correctly installed.

Install the brake pedal actuating rod retaining pin.





4. Install the clutch pedal assembly nuts.





5. Attach the clutch slave cylinder supply line to the front bulkhead and install the clip.





6. NOTE: The clutch position switch (red) is not adjustable.

Pull out the starter safety switch, speed control deactivation switch and brake lamp switch plungers until they are fully extended.
^ Measure the plunger length.
^ Speed control deactivation switch (green) XX mm = 24 mm.
^ Brake lamp switch (grey) XX mm = 21 mm.
^ Starter safety switch (black) XX mm = 26 mm.





7. CAUTION: When installing the switches, the brake lamp switch is rotated counterclockwise and the remaining switches are rotated clockwise. Failure to follow this instruction will result in the switch plungers binding inside the switch.

CAUTION: Make sure the switches are correctly installed.

NOTE: The speed control deactivation switch and the stop lamp switch are automatically adjusted during installation.

NOTE: A slight ratcheting noise and feel during installation of the speed control deactivation switch and the brake lamp switch is normal.

Install the switches to the pedal assembly.
1. Speed control deactivation switch (green).
2. Brake lamp switch (grey).
3. Clutch position switch (red).
4. Starter safety switch (black).

8. NOTE: The colors of the electrical connectors and the switches are identical.

Connect the electrical connectors to the pedal assembly switches.

9. NOTE: A slight ratcheting noise and feel during switch adjustment is normal.

Adjust the starter safety switch (black) by pressing and then releasing the clutch pedal.





10. NOTE: Install new O-ring seals.

Connect the clutch master cylinder and slave cylinder fluid supply lines to the clutch master cylinder, then insert the clips.





11. Connect the hood release cable and the Data Link Connector to the instrument panel lower panel.





12. Install the instrument panel lower panel trim to the instrument panel.
1. Secure the fastener.
2. Install the screws.





13. Attach the Central Junction Box (CJB) to the mounting bracket.
1. Install the retaining bolt.
2. Attach the clip.
14. Install the air cleaner.
15. Fill the brake fluid reservoir to the MAX mark with the specified fluid.
16. Bleed the hydraulic clutch system.
17. Connect the battery ground cable.