The clutch master cylinder is located in the engine compartment, on the left-side of the firewall, above or near the steering column.
REMOVAL & INSTALLATION
See Figure 1
- Disconnect the negative battery cable.
- Remove the hush panel or lower filler panel from under the dash.
- If necessary, remove the lower left A/C duct.
- Remove the pushrod retainer, then disconnect the pushrod from the clutch pedal.
- Either disconnect the reservoir hose (if the reservoir is not being removed or if there is no clearance for reservoir removal with the hose installed) or remove the reservoir retainers.
- Disconnect the slave cylinder hydraulic line from the clutch master cylinder. Immediately plug all openings to prevent system contamination or excessive fluid loss.
- Remove the master cylinder-to-cowl brace nuts. Remove the master cylinder and overhaul (if necessary).
- Using a putty knife, carefully clean all old gasket material from the master cylinder and cowl mounting surfaces.
- Install the master cylinder to the cowl using a new gasket. Tighten the retainers to 13 ft. lbs. (18 Nm).
- Remove the caps, then connect the slave cylinder hydraulic line to the master cylinder assembly.
- Either connect the reservoir hose or install the reservoir and secure using the retainers.
- Connect the pushrod to the pedal and secure using the retainer.
- If removed, install the lower left A/C duct.
- Install the hush/filler panel.
- Connect the negative battery cable.
- Properly refill the master cylinder reservoir, then bleed the system of air and check for fluid leaks.
See Figure 2
Most vehicles covered by this guide utilize an easily rebuilt clutch master cylinder assembly. The following procedure may be used for most hydraulic clutch master cylinders.
- Remove the filler cap and drain fluid from the master cylinder.
- Remove the reservoir adapter and seal from the master cylinder.
- Pull back the dust cover and remove the snapring from the end of the assembly.
- Remove the pushrod assembly. Shake the pushrod and plunger out of the cylinder body. If difficulty is encountered, gently tap the master cylinder assembly on a block of wood to help 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.
- Remove the spring, support, seal and the shim, from the rear of the plunger assembly.
- Using clean brake fluid, clean all of the parts.
- Inspect the cylinder and 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 (DOT 3), fit the plunger seal to the plunger and reverse the removal procedures.
- Insert the plunger assembly, with the 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. Install the dust cover onto the master cylinder. Lubricate the inside of the dust cover with Girling® Rubber Grease or equivalent.
Be careful not to use any lubricant that will deteriorate rubber dust covers or seals.