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Clutch Master Cylinder Replacement

WARNING: This page is about a different variant/trim than selected.
NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or plastic, wash it off immediately with water.
  • Plug the ends of the hoses and joints to prevent spilling brake fluid.
  • Put on gloves to protect your hands.
  1. Secure the hood in the wide open position (support rod in the lower hole).
  2. Remove and discard the brake fluid from the clutch reservoir with a syringe or other suitable device.
  3. Remove the air cleaner (see AIR CLEANER ELEMENT INSPECTION/REPLACEMENT ).
  4. Remove the harness clamp (A), then remove the harness holder (B) from the bracket (C).
    Fig 1: Identifying Harness Clamp, Harness Holder Of Bracket And Reservoir Hose With Clip
    G06950594Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove the reservoir hose (D) from the reservoir hose clip (E).
  6. Disconnect clutch line A from the clutch master cylinder (B).
    NOTE:
    • To prevent spills, cover the line joint with rags or shop towels.
    • Loosen the flare nut (C) while holding the clutch line connector (D) using a wrench.
      Fig 2: Identifying Clutch Line Of Clutch Master Cylinder And Clutch Line Connector With Flare Nut
      G06950595Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Remove the driver's dashboard undercover (see DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION ).
  8. Pry out the lock pin (A), and pull the clevis pin (B) out of the clevis. Remove the master cylinder mounting nuts (C).
    Fig 3: Identifying Lock Pin, Clevis Pin Of Clevis And Master Cylinder Mounting Nuts
    G06950596Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Remove the clutch master cylinder (A) and the clutch master cylinder seal (B) from the body.
    Fig 4: Identifying Clutch Master Cylinder And Clutch Master Cylinder Seal Of Body
    G06950597Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Disconnect the reservoir hose (C).
    NOTE: Inspect the hose. If the hose has damage, leaks, interference, or twisting, replace it.
  11. Remove the retaining clip (A), then remove the clutch line connector (B) and the O-ring (C) from the master cylinder (D).
    Fig 5: Identifying Retaining Clip, Clutch Line Connector And O-Ring Of Master Cylinder
    G06950598Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Inspect the length (A) of the clutch master cylinder push rod to the figure as shown.
    NOTE: When installing the used clutch master cylinder only.
    Fig 6: Clutch Master Cylinder Push Rod Length With Torque Specifications
    G06950599Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install the clutch line connector (A) with a new O-ring (B), then set in a new retaining clip (C) to the master cylinder (D).
    NOTE:
    • Apply the silicone grease (P/N 08C30-B0234M) on the O-ring and the joint part (E) of the clutch line connector.
    • Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
      Fig 7: Identifying Clutch Line Connector With O-Ring And Retaining Clip Of Master Cylinder
      G06950600Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. To prevent the retaining clip (A) from coming off, pry apart the tip (B) of the clip with a flat-tipped screwdriver.
    Fig 8: Prying Retaining Clip Tip Using Flat-Tipped Screwdriver
    G06950601Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Install the reservoir hose (A) and adjust the hose clamp (B) positions and its direction.
    NOTE: When attaching the reservoir hose, align the blue mark (C) on the hose to the rib (D).
    Fig 9: Identifying Reservoir Hose, Hose Clamp And Blue Mark On Hose Of Rib
    G06950602Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Install a new master cylinder seal (E) and the clutch master cylinder (F) to the body.
  17. Install the master cylinder mounting nuts (A).
    NOTE:
    • Connect the clevis (B) to the clutch pedal, then apply multipurpose grease between the clutch pedal and the clevis.
    • Wipe off any excess grease.
      Fig 10: Clutch Pedal Clevis, Lock, Clevis Pins And Master Cylinder Mounting Nuts With Torque Specifications
      G06950603Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Apply multipurpose grease to the clevis pin (C). Slide the clevis pin into the clevis, then install a lock pin (D).
  19. Connect clutch line A to the clutch master cylinder (B).
    NOTE: Tighten the flare nut (C) while holding the clutch line connector (D) using a wrench.
    Fig 11: Clutch Line Of Clutch Master Cylinder And Clutch Line Connector With Flare Nut With Torque Specifications
    G06950604Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Install the harness holder (A) to the bracket (B), then install the harness clamp (C).
    Fig 12: Identifying Harness Holder Of Bracket, Harness Clamp And Reservoir Hose Of Reservoir Hose Clip
    G06950605Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Install the reservoir hose (D) to the reservoir hose clip (E).
  22. Install the air cleaner (see AIR CLEANER ELEMENT INSPECTION/REPLACEMENT ).
  23. Bleed the clutch hydraulic system (see CLUTCH HYDRAULIC SYSTEM BLEEDING  ).
  24. Adjust the clutch pedal, clutch pedal position switch A, clutch pedal position switch B, and clutch pedal position switch C (see CLUTCH PEDAL AND CLUTCH PEDAL POSITION SWITCH ADJUSTMENT  ).
  25. Check the clutch operation, and check for leaks.
  26. Install the driver's dashboard undercover (see DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION ).
  27. Test-drive the vehicle.
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