Kia Sportage 1998-02

Master Cylinder

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Overhaul




WARNING
The clutch hydraulic system uses brake fluid to control hydraulic operation. Never reuse brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the master cylinder from the vehicle and secure on a bench top vise.
  4.  
  5. Press down on the piston and remove the retaining clip with needle-nose pliers.
  6.  
  7. With retaining clip removed, use compressed air to remove the piston and secondary cup assembly, primary cup and return spring.
  8.  
  9. Use brake fluid to clean inner parts.
  10.  
  11. After cleaning, inspect and replace the following parts as necessary:
    1. Worn or damaged clutch master cylinder bore and piston.
    2.  
    3. Weak return spring.
    4.  
    5. Worn or damaged primary or secondary cups.
    6.  

  12.  

Assembly:

  1. Coat the piston and cups with clean brake fluid.
  2.  
  3. Insert return spring, primary cup, piston and secondary cup assembly, and piston stop washer into cylinder bore.
  4.  
  5. Install retaining clip using needle-nose pliers.
  6.  
  7. Snap in bushing and reservoir tank hose.
  8.  
  9. Fill cylinder with new brake fluid and operate the piston until fluid comes out of outlet.
  10.  
  11. Reinstall the master cylinder.
  12.  
  13. Connect the negative battery cable.

    Click image to see an enlarged view

    Fig. Depress the piston and remove the retaining clip as shown



    Click image to see an enlarged view

    Fig. Exploded view of clutch master cylinder

  14.  

Removal & Installation




WARNING
The clutch hydraulic system uses brake fluid to control hydraulic operation. Never reuse brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the reservoir tank hose from the cylinder body.
    NOTE
    To prevent loss of brake fluid during clutch master cylinder removal, the disconnected hydraulic fluid transfer hose must be plugged or directed into suitable container.

  4.  
  5. Using a line wrench, disconnect the hydraulic line from the cylinder body.
  6.  
  7. From the passenger compartment, remove the upper mounting nut.
  8.  
  9. From the engine compartment, remove the lower mounting nut.
  10.  
  11. Remove the master cylinder and gasket from the vehicle.
  12.  

To install:

  1. Using a new gasket, place the master cylinder on the vacuum booster and loosely tighten the lower mounting nut.
  2.  
  3. From inside the vehicle, install the upper mounting nut and tighten to 17 ft. lbs. (23 Nm).
  4.  
  5. From outside the vehicle, tighten the lower mounting bolt to 17 ft. lbs. (23 Nm).
  6.  
  7. Connect the steel line and tighten using a line wrench.
  8.  
  9. Connect the reservoir hose.
  10.  
  11. Refill the fluid to the proper level.
  12.  
  13. Bleed and adjust the system as necessary.
  14.  
  15. Connect the negative battery cable.

    Click image to see an enlarged view

    Fig. Clutch master cylinder and related components

  16.  

 
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