REMOVAL & INSTALLATION
See Figures 1, 2 and 3
The clutch hydraulic system is serviced as a complete unit; it has been bled of air and filled with fluid. Individual components of the system are not available separately.
Remove the lock pin and disconnect the master cylinder push rod from the clutch pedal.
- On 2.0L and 2.3L gasoline engines, remove the bolt attaching the dust shield to the clutch housing and remove the dust shield. Push the slave cylinder rearward to disengage from the recess in the housing lugs, then slide outward to remove.
- On 2.8L gasoline engines and 2.2L diesel engines, remove the bolts attaching the slave cylinder to the clutch housing and remove the slave cylinder. Disengage the push rod from the release lever as the cylinder is removed. Retain the push rod to release lever plastic bearing inserts.
- Remove the two bolts attaching the master cylinder to the firewall.
- Remove the two bolts attaching the fluid reservoir to the cowl access cover.
- Remove the master cylinder from the opening in the firewall and remove the hydraulic system assembly upward and out of the engine compartment.
- Position the hydraulic system downward into the engine compartment. The slave to master cylinder tube routing is to be above the brake tubes and below the steering column shaft.
On 6-2.8L vehicles, the tube must lay on top of the clutch housing.
- Insert the master cylinder push rod through the opening in the firewall, position the master cylinder on the firewall, and install the attaching bolts. Torque the bolts to 15-20 ft. lbs.
- Position the fluid reservoir on the cowl opening cover and install the attaching bolts. Torque the attaching bolts to 15-20 ft. lbs.
- Install the slave cylinder by pushing the slave cylinder push rod into the cylinder, engage the push rod and plastic bearing inserts into the release lever, and attach the cylinder to the clutch housing.
With a new system, the slave cylinder contains a shipping strap that pre-positions the push rod for installation, and also provides a bearing insert. Following installation of the slave cylinder, the first actuation of the clutch pedal will break the shipping strap and give normal system operation.
- 4-2.0L,2.3L engines: Snap the dust shield into position. Install the retaining bolt and tighten to 5-10 ft. lbs.
- 6-2.8L gasoline and 4-2.2L diesel engines: Install the bolts attaching the slave cylinder to the clutch housing and torque them to 15-20 ft. lbs.
- Clean and apply a light film of oil to the master cylinder push rod bushing and install the bushing and push rod to the clutch pedal. Retain with the lock pin.
- Depress the clutch pedal at least 10 times to verify smooth operation and proper clutch release.
- Disconnect the negative battery cable.
- Disconnect the clutch master cylinder pushrod from the clutch pedal.
- Remove the switch from the master cylinder assembly, if equipped.
- Remove the screw retaining the fluid reservoir to the cowl access cover.
- Disconnect the tube from the slave cylinder and plug both openings.
- Remove the bolts retaining the clutch master cylinder to the dash panel and remove the clutch master cylinder assembly.
- Install the pushrod through the hole in the engine compartment. Make certain it is located on the correct side of the clutch pedal. Place the master cylinder assembly in position and install the retaining bolts. Tighten to 8-2 ft. lbs. (1-16Nm).
- Insert the coupling end into the slave cylinder and install the tube into the clips.
- Fit the reservoir on the cowl access cover and install the retaining screws.
- Replace the retainer bushing in the clutch master cylinder pushrod if worn or damaged. Install the retainer and pushrod on the clutch pedal pin. Make certain the bushing is fitted correctly with the flange of the bushing against the pedal blade.
- Install the switch.
- Bleed the system.
- Reconnect the negative battery cable.