Isuzu I-280, I-350 2005-06

Master Cylinder

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Removal & Installation




NOTE
A new retainer (3) is required after removal.

  1. Complete the following in order to disengage the retainer (3) from the clutch pedal pin.
    1. Insert a flat bladed tool (4) between the clutch master cylinder push rod (1) and the clutch pedal (2).
    2.  
    3. Pry the clutch master cylinder push rod (1) away from the clutch pedal assembly (2). Discard the retainer (3).
    4.  

  2.  
  3. Raise and support the vehicle.

    Click image to see an enlarged view

    Fig. Disengaging the retainer from the clutch pedal pin

  4.  
  5. Using the Hydraulic Clutch Line Separator J-43271, push back the with plastic sleeve on the quick connect in order to separate the hydraulic clutch hose from the clutch actuator quick connect. It is not necessary to plug the lower hose end or slave cylinder fitting as they are equipped with check valves, only minimal fluid loss may be experienced.
  6.  
  7. Disconnect the clutch hydraulic hose retainer from the inner fender.
  8.  
  9. Lower the vehicle.

    Click image to see an enlarged view

    Fig. Separating the hydraulic clutch hose from the clutch actuator quick connect

  10.  
  11. Rotate the clutch master cylinder clockwise 1 / 8 turn.

    Click image to see an enlarged view

    Fig. Rotating the clutch master cylinder

  12.  
  13. Remove the clutch master cylinder with hydraulic hose from the cowl.

    Click image to see an enlarged view

    Fig. Removing clutch master cylinder with hydraulic hose from the cowl

  14.  

To install:

  1. Route the clutch hydraulic hose with master cylinder under the brake booster.
  2.  
  3. With the clutch fluid reservoir cap at the 1:30 position. Insert the clutch master cylinder into the cowl.
  4.  
  5. Rotate the clutch master cylinder counter clockwise 1/8 turn until fully seated. The clutch fluid reservoir cap will be vertical at the 12:00 position when the clutch master cylinder is properly installed.
  6.  
  7. Raise the vehicle.
    WARNING
    Ensure the clutch hydraulic hose does not come in contact with any sharp or potentially hot surfaces.

  8.  
  9. Push the clutch hydraulic hose quick connect fitting into the clutch slave cylinder, until a -click- is heard.
  10.  
  11. Tug gently on the clutch hydraulic hose to ensure proper retention into the clutch slave cylinder.
  12.  
  13. Connect the clutch hydraulic hose retainer to the inner fender.
  14.  
  15. Lower the vehicle.
  16.  
  17. Insert a new retainer into the clutch master cylinder push rod.
  18.  
  19. Push the clutch master cylinder push rod onto the clutch pedal pin to secure.
  20.  
  21. Adjust the clutch release switch by performing the following:
    1. Rotate the clutch release switch counterclockwise, allowing the retainer to release.
    2.  
    3. Pull the clutch pedal to full stop.
    4.  
    5. While holding the clutch pedal at full stop, push the switch inward fully until the switch body contacts the clutch pedal arm. At this point the plunger in the switch should be pushed in.
    6.  
    7. Rotate the switch (4) clockwise until a -click- is heard.

      Click image to see an enlarged view

      Fig. Adjusting the clutch release switch

    8.  

  22.  
  23. Adjust the clutch pedal position switch by pushing the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. Then depress the clutch pedal all the way to the floor.
  24.  
  25. Bleed the clutch hydraulic system, only if necessary.
  26.  

 
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