The clutch master cylinder is located in the engine compartment, on the left side of the firewall, above the steering column.
REMOVAL & INSTALLATION
See Figures 1 and 2
- Disconnect negative battery cable.
- Remove hush panel from under the dash.
- Disconnect pushrod from clutch pedal.
- Disconnect hydraulic line from the clutch master cylinder using a flare nut wrench.
- Remove the master cylinder-to-cowl brace nuts. Remove master cylinder and overhaul (if necessary).
- Using a putty knife, clean the master cylinder and cowl mounting surfaces.
- Install the master cylinder-to-cowl brace nuts and master cylinder.
- Connect hydraulic line to the clutch master cylinder using a flare nut wrench.
- Connect pushrod to clutch pedal.
- Install hush panel to the dash.
- Connect negative battery cable.
- Tighten the master cylinder-to-cowl brace nuts to 10-15 ft. lbs. (14-20 Nm). Fill master cylinder with clean, fresh hydraulic fluid conforming to DOT 3 specifications.
- Bleed the hydraulic clutch system and check for leaks.
See Figure 3
- Remove the clutch master cylinder assembly from the vehicle.
- Remove the filler cap and drain the fluid from the master cylinder.
- Remove the reservoir and seal from the master cylinder. Pull back the dust cover and remove the snapring.
- Remove the pushrod assembly. Using a block of wood, tap the master cylinder on it to eject the plunger assembly from the cylinder bore.
- Remove the seal (carefully) from the front of the plunger assembly, ensuring no damage occurs to the plunger surfaces.
- From the rear of the plunger assembly, remove the spring, the support, the seal and the shim.
- Using clean brake fluid, clean all of the parts.
- Inspect the cylinder bore and the plunger for ridges, pitting and/or scratches; the dust cover for wear and cracking; replace the parts if any of the conditions exist.
- Use new seals, lubricate all of the parts in clean brake fluid, and fit the plunger seal to the plunger.
- Insert the plunger assembly, valve end leading into the cylinder bore (easing the entrance of the plunger seal).
- Position the pushrod assembly into the cylinder bore, then install a new snapring to retain the pushrod. Lubricate the inside of the dust cover with Girling® Rubber Grease or equivalent. Install dust cover onto the master cylinder.
Be careful not to use any lubricant that will deteriorate rubber dust covers or seals.
- Install the master cylinder assembly to the vehicle.