Isuzu Cars and Trucks 1981-1991

Clutch Master Cylinder

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REMOVAL AND INSTALLATION
  1. Disconnect the negative battery cable.
  2.  
  3. From inside the vehicle, disconnect the master cylinder pushrod from the clutch pedal.
  4.  
  5. Using a flarenut wrench, remove the fluid line from the master cylinder.
  6.  
  7. Remove the cylinder retaining bolts from the firewall and remove the cylinder.
  8.  

To install:

  1. Install the cylinder and retaining bolts to the firewall.
  2.  
  3. Using a flarenut wrench, install the fluid line to the master cylinder.
  4.  
  5. From inside the vehicle, connect the master cylinder pushrod to the clutch pedal.
  6.  
  7. To bleed the hydraulic system , fill the reservoir with DOT 3 brake fluid to the top and install the cap. Open the slave cylinder bleeder screw. With an assistance pumping the clutch pedal slowly, watch the bleeder until clean fluid comes out. Close the bleeder. Open the bleeder and have the assistant push the pedal to the floor and hold. Close the bleeder and release the pedal. NEVER ALLOW THE FLUID RESERVOIR TO RUN DRY. Repeat until all air bubbles are removed. Repeat the procedure at the damper valve, if so equipped.
  8.  
  9. Connect the negative battery cable and check operation.
  10.  



Click image to see an enlarged view

Fig. Clutch master cylinder and pedal height adjustment

OVERHAUL
  1. Remove the master cylinder from the vehicle as outlined in this Section.
  2.  
  3. Remove the yoke and nut from the pushrod.
  4.  
  5. Remove the snapring from the cylinder housing and remove pushrod and boot.
  6.  
  7. Using compressed air if needed, blow the piston from the housing.
  8.  
  9. Remove the reservoir clamp and reservoir.
  10.  
  11. Clean all parts in denatured alcohol and dry with compressed air.
  12.  

To assemble

  1. Install the reservoir and clamp.
  2.  
  3. Coat all rubber parts with rubber grease or clean brake fluid. Install the piston into the bore.
  4.  
  5. Install the pushrod, boot and snapring to the cylinder housing.
  6.  
  7. Install the yoke and nut to the pushrod.
  8.  
  9. Install the master cylinder to the vehicle as outlined in this Section.
  10.  



Click image to see an enlarged view

Fig. Exploded view of the clutch master cylinder

 
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