REMOVAL & INSTALLATION
The clutch release cylinder is mounted to the left-hand side of the transmission.
- Raise and support the vehicle on jackstands.
- Position a drain pan under the release cylinder.
- Loosen the bleeding valve and let the system drain into the pan. Used fluid should never be reused.
- Remove the eye bolt holding the clutch hose to the release cylinder. Discard the two gaskets from this connection, new ones will be needed for reassembly.
- Remove the two mounting bolts, then remove the release cylinder from the transmission.
- Mount the clutch release cylinder to the transmission. Tighten the mounting bolts to 20-30 ft. lbs. (31-42 Nm).
- Using new gaskets, attach the clutch hose with the eye bolt. Tighten the eye bolt to 14-18 ft. lbs. (20-25 Nm).
- Fill and bleed the system. Check for fluid leaks.
- Lower the vehicle back to the ground.
- With the cylinder removed from the vehicle, remove the valve plate and spring from the fluid port.
- Remove the pushrod and boots.
- Mount the cylinder in a bench vise. Cover or block the end of the cylinder to prevent the piston from flying out. Use compressed air to force the piston out of the bore. Apply the air slowly to prevent fluid from splashing.
- Check the inner surfaces of the cylinder bore for any sign of scratching or rust. Check the piston surface for the same condition and replace it if needed. Inspect the edges of the piston cup; replace if excessive wear or fatigue is found.
- Coat the internal components is clean fresh brake fluid. Coat the inside of the cylinder. Install the spring and the piston and cup into the cylinder.
- Install the boots and pushrod. Install the spring and valve plate.
- Install the unit to the vehicle. Tighten the mounting bolts to 26 ft. lbs. (35 Nm). The end of the pushrod should be greased before installation as should its hole in the clutch release arm. If the bleeder screw was removed, it should be tightened to 8 ft. lbs. (11 Nm).
- Connect the clutch fluid tube, tightening the hose fitting to 16 ft. lbs. (22 Nm).
Make sure the clutch master cylinder is filled with the correct fluid (DOT 3 brake fluid). Loosen the bleeder screw at the slave cylinder. Push the clutch pedal down slowly until all air is expelled (bubbles in the fluid); do not release the pedal but hold it depressed. Retighten the bleeder screw. Release the clutch pedal. Refill the master cylinder to the correct level.
This process may need repetition several times; the key point to remember is that the clutch pedal MUST be held down until the bleeder screw is tightened. If the pedal is released with the bleeder open, air is sucked into the system.
Continue bleeding the system until no air is expelled with the fluid. When a steady stream of fluid is obtained, tighten the bleeder and top off the clutch fluid reservoir.