Lexus Car ES, IS, LS 1998-06

Master Cylinder

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Overhaul



Assembly


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Fig. Coat parts with lithium soap base glycol grease.-IS 300

  1. Coat parts with lithium soap base glycol grease, as shown.
  2.  
  3. Insert piston and spring into cylinder.
  4.  
  5. Install the washer to the push rod.
  6.  
  7. Push the push rod to the piston, using snap ring pliers, install the snap ring.
  8.  
  9. Install the boot.
  10.  
  11. Temporarily install the lock nut and clevis.
  12.  
  13. Install the reservoir tank and a new grommet.
  14.  
  15. Using a pin punch (5mm) and a hammer, drive in the slotted spring pin.
  16.  

Disassembly


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Fig. Using a pin punch (5mm) and a hammer to drive out the slotted spring pin.-IS 300

  1. Using a pin punch (5mm) and a hammer, drive out the slotted spring pin, then remove the reservoir tank and grommet.
  2.  
  3. Loosen the lock nut to remove the clevis and remove the lock nut.
  4.  
  5. Remove the boot.
  6.  
  7. While pushing the push rod, using snap ring pliers remove the snap ring.
  8.  
  9. Remove the push rod and washer.
  10.  
  11. Remove the piston and spring.
  12.  

Removal & Installation





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Fig. Exploded view of the clutch master cylinder.-IS 300

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  4.  
  5. Drain out clutch fluid with a syringe.
  6.  
  7. Remove the lower finish panel.
  8.  
  9. Using SST 09023-00101, disconnect the clutch line. Use a container to catch the fluid.
  10.  
  11. Using needle nose pliers, remove the clip, pin and washer.
  12.  
  13. Remove the 2 mounting nuts and pull out the clutch master cylinder.
  14.  

To install:

  1. Place the clutch master cylinder into position on the vehicle and install the 2 mounting bolts. Tighten the bolts to 9 ft. lbs. (12 Nm).
  2.  
  3. Install the washer, pin and clip
  4.  
  5. Connect the clutch line and tighten the union to 11 ft. lbs. (15.2 Nm).
  6.  
  7. Install the lower finish panel.
  8.  
  9. Refill the clutch fluid system.

    Click image to see an enlarged view

    Fig. Adjusting the clutch pedal height.-IS 300

  10.  
  11. Inspect and adjust clutch pedal height as follows:


    1. Remove the lower finish panel.
    2.  
    3. Loosen the lock nut and clutch switch until the height is correct. Pedal height from asphalt sheet: 6.38-6.77 inches (162-172mm)
    4.  
    5. Tighten the lock nut to 12 ft. lbs. (15.7 Nm).
      NOTE
      Before rotating the clutch switch for pedal height adjustment, disconnect the clutch switch connector.

    6.  
    7. Install the lower finish panel.
    8.  

  12.  
  13. Connect the negative battery cable.
  14.  



Click image to see an enlarged view

Fig. Exploded view of the clutch master cylinder.-IS 250

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  4.  
  5. Remove the left front door scuff plate.
  6.  
  7. Remove the left front door opening trim cover.
  8.  
  9. Remove left side instrument panel.
  10.  
  11. Remove No. 1 instrument panel under cover sub-assembly.
  12.  
  13. Remove lower instrument panel finish panel sub-assembly.
  14.  
  15. Remove the driver side knee airbag assembly.
  16.  
  17. Disconnect the 3 connectors and clamp.
  18.  
  19. Disconnect the clutch reservoir tube. Use a container to catch the fluid.
  20.  
  21. Using SST 09023-00101, disconnect the clutch line from the clutch master cylinder. Use a container to catch the fluid.
  22.  
  23. Remove the 2 nuts, bolt and clutch pedal support.
  24.  
  25. Remove the nut and clutch start switch assembly from the clutch pedal support.
  26.  
  27. Remove the clutch master cylinder push rod clevis clip and pin.
  28.  
  29. Remove the clutch reservoir tube.
  30.  
  31. Remove the 2 bolts and clutch master cylinder assembly.
  32.  

To install:

  1. Install the clutch master cylinder assembly with the 2 bolts and tighten to 9 ft. lbs. (12 Nm).
  2.  
  3. Connect the clutch reservoir tube.
  4.  
  5. Install the clutch master cylinder push rod clevis pin as follows:


    1. Apply MP grease to the contact surface of the pin and a clevis bushing.
    2.  
    3. Connect the clevis to the clutch pedal with the pin. Install the pin from the left side of the vehicle.
    4.  
    5. Install the new clip to the pin.
    6.  

  6.  
  7. Install the clutch start switch assembly with the nut and tighten to 12 ft. lbs. (16 Nm).
  8.  
  9. Install the clutch pedal support with the 2 nuts and bolt and tighten to 14 ft. lbs. (19 Nm).
  10.  
  11. Using SST 09023-00101, connect the clutch line. Tighten the fitting to 11 ft. lbs. (15 Nm).
    NOTE
    Use a torque wrench with a fulcrum length of 11.81 inches (300mm).

  12.  
  13. Connect the clutch reservoir tube.
  14.  
  15. Connect the 3 wire harness connectors and clamp.
  16.  
  17. Fill the brake reservoir with the brake fluid and bleed the clutch system.
  18.  
  19. Check for leakage in the clutch system.

    Click image to see an enlarged view

    Fig. Adjusting the clutch pedal height.-IS 250

  20.  
  21. Inspect and adjust clutch pedal height as follows:


    1. Turn back the floor carpet.
    2.  
    3. Check that the pedal height is correct. Pedal height from asphalt sheet: 6.8149-7.2086 inches (173.1-183.1mm)
    4.  
    5. Adjust pedal height.
    6.  
    7. Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut to 12 ft. lbs. (16 Nm).
    8.  

  22.  
  23. Install the driver side knee airbag assembly.
  24.  
  25. Install lower instrument panel finish panel sub-assembly.
  26.  
  27. Install No. 1 instrument panel under cover sub-assembly.
  28.  
  29. Install left side instrument panel.
  30.  
  31. Install the left front door opening trim cover.
  32.  
  33. Install the left front door scuff plate.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Inspect the brake fluid level in the reservoir.
  38.  
  39. Perform initialization procedure.
  40.  
  41. Inspect the SRS warning light as follows:


    1. Turn the engine switch on (IG), and check that the SRS warning light comes on for approximately 6 seconds (primary check).
    2.  
    3. Check that the SRS warning light goes off approximately 6 seconds after the engine switch is turned on (IG) (constant check).
    4.  

  42.  

 
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