Hyundai Coupes/Sedans 1994-1998 Repair Guide

Clutch Master Cylinder

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REMOVAL & INSTALLATION



See Figures 1 and 2



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Fig. Fig. 1: Exploded view of the clutch hydraulic system



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Fig. Fig. 2: Lubricate the clevis pin and washers at the specified points

  1. Unscrew the reservoir cap.
  2.  
  3. Loosen the bleeder plug and drain the clutch fluid into a suitable container.
  4.  
  5. Disconnect and plug the hydraulic line at the release cylinder.
  6.  
  7. From inside the vehicle, remove the split pin, clevis pin and washer from the clutch pedal to release the master cylinder pushrod.
  8.  
  9. Remove the clutch fluid reservoir tank mounting bolt.
  10.  
  11. Loosen the hydraulic line clamps to permit movement of the clutch tube.
  12.  
  13. Disconnect the hydraulic line from the master cylinder.
  14.  
  15. Remove the two nuts and pull the master cylinder and gasket from the firewall.
  16.  
  17. Inspect the gasket for damage and replace as required.
  18.  

To install:
  1. Position the master cylinder assembly with gasket onto the fire wall and tighten mounting nuts and bolts to 7-10 ft. lbs. (9-14 Nm).
  2.  
  3. Connect the hydraulic line to the master cylinder and tighten to 9-12 ft. lbs. (13-17 Nm).
  4.  
  5. Connect the pushrod to the clutch pedal and insert the clevis pin. Secure the clevis pin with the split pin.
  6.  
  7. Fill and bleed the system.
  8.  
  9. Adjust the clutch pedal height and free play.
  10.  
  11. When the pin play adjustment is complete, lubricate the clevis pin with a small amount of wheel bearing or multipurpose grease.
  12.  
  13. Check the clutch for proper performance.
  14.  

 
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