REMOVAL & INSTALLATION
- Raise the vehicle and safely support with jackstands.
- Unscrew the hydraulic line from the release cylinder.
- Unhook the release fork return spring from the cylinder.
- Unfasten the nuts which secure the release cylinder to the transmission/transaxle.
- Installation is performed in the reverse order of removal. Bleed the hydraulic system as detailed below, and adjust the release fork free-play as previously described.
See Figure 1
- Thoroughly clean the outside of the cylinder body.
- Drain the hydraulic fluid from the cylinder.
- Remove the boot from the cylinder.
- Release the wire piston stop with a screwdriver and withdraw the stop washer.
- Withdraw the piston, piston cups, and return spring from the cylinder bore.
- Wash all the parts in clean hydraulic (brake) fluid.
- Examine the piston cups. If they are damaged, softened, or swollen, replace them with new ones.
- Check the piston and bore for scoring or roughness.
- Use a wire gauge to check the clearance between the piston and its bore. Replace either the piston or the cylinder if the clearance is greater than 0.006 in. (0.15mm).
- Dip the piston and cups in clean hydraulic (brake) fluid.
- Fit the return spring into the cylinder.
- Insert the primary cup into the bore so that its flat side is facing the piston.
- Place the secondary cup on the piston and insert them in the cylinder bore.
- Install the stop washer and the wire piston stop.
- Fit the boot on the cylinder.
HYDRAULIC SYSTEM BLEEDING
See Figure 2
- Remove the rubber cap from the bleeder screw on the release cylinder.
- Place a bleeder tube over the end of the bleeder screw.
- Submerge the other end of the tube in a jar half-filled with hydraulic (brake) fluid.
- Depress the clutch pedal fully and allow it to return slowly.
- Keep repeating Step 4 while watching the hydraulic fluid in the jar. As soon as the air bubbles disappear, close the bleeder screw.
During the bleeding procedure, the reservoir must be kept at least3/4full.
- Remove the tube and refit the rubber cap. Fill the reservoir with hydraulic fluid.