Clutch Master Cylinder: Service and Repair

REMOVAL
1. REMOVE FILLER CAP FROM RESERVOIR
2. DRAW OUT BRAKE FLUID WITH SYRINGE

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.

3. w/ ABS: REMOVE ABS ACTUATOR
4. DISCONNECT RESERVOIR HOSE FROM MASTER CYLINDER
Using pliers, slide the clip toward the reservoir and disconnect the reservoir hose. Use a container to catch the fluid.





5. DISCONNECT CLUTCH LINE FROM MASTER CYLINDER
Using SST, disconnect the line. Use a container to catch the fluid.
SST 09023-00100
6. REMOVE RETURN SPRING, CLIP AND CLEVIS PIN
a. Using needle-nose pliers, remove the return spring.
b. Using needle-nose pliers, remove the clip.
c. Remove the clevis pin.





7. REMOVE MASTER CYLINDER
Remove the 2 nuts and master cylinder from the body.

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 and grommet.
2. REMOVE CLEVIS AND BOOT
a. Loosen the lock nut to remove the clevis and remove the lock nut.
b. Remove the boot.





3. REMOVE PUSH ROD
a. While pushing the push rod, using snap ring pliers, remove the snap ring.
b. Remove 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 AND BOOT
a. Install the washer to the push rod.
b. Push the push rod to the piston, using snap ring pliers, install the snap ring.
c. Install the boot.
4. TEMPORARILY INSTALL LOCK NUT AND CLEVIS





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

INSTALLATION
1. INSTALL MASTER CYLINDER
Install the master cylinder to the body with the 2 nuts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
2. INSTALL CLEVIS PIN, CLIP AND RETURN SPRING
a. Install the clevis pin.
b. Using needle-nose pliers, install the clip.
c. Using needle-nose pliers, install the return spring.





3. CONNECT CLUTCH LINE TO MASTER CYLINDER
Using SST, connect the clutch line.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
4. CONNECT RESERVOIR HOSE TO MASTER CYLINDER
Connect the reservoir hose to the inlet union and using pliers, install the clip.
5. w/ ABS: INSTALL ABS ACTUATOR
6. FILL RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM
7. CHECK FOR LEAKS
8. ADJUST CLUTCH PEDAL
9. FILL BRAKE FLUID UP TO MAX. LINE ON RESERVOIR
10. INSTALL FILLER CAP TO RESERVOIR