Neon, 2000-2005

Master Cylinder

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Removal & Installation



2.0L Engines

NOTE
These models are equipped with a one-piece master/slave cylinder assembly. If the master cylinder requires replacement, the master AND slave cylinder must be replaced with a two-piece -quick-connect- system. If the slave cylinder requires replacement, the slave cylinder is serviced separately.


NOTE
Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the slave cylinder assembly.

  1. Remove air cleaner assembly.
  2.  
  3. Disconnect battery negative cable.
  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Remove slave cylinder from transaxle.

    Click image to see an enlarged view

    Fig. Clutch slave cylinder (1) and bracket (2) at transaxle-2.0L models

    Clutch slave cylinder (1) and bracket (2) at transaxle-2.0L models
  8.  
  9. Remove hydraulic hose from left rail retainers.

    Click image to see an enlarged view

    Fig. Clutch master cylinder (1), reservoir (2) and retainer clips (3) and (4)

    Clutch master cylinder (1), reservoir (2) and retainer clips (3) and (4)
  10.  
  11. Lower vehicle.
  12.  
  13. Remove PDC bracket and position out of way.
  14.  
  15. Remove lower instrument panel bezel.
  16.  
  17. Remove clip and disconnect the brake booster input rod from the brake pedal pin.

    Click image to see an enlarged view

    Fig. Clip (1) and brake booster mounting nuts (2) and (3)

    Clip (1) and brake booster mounting nuts (2) and (3)
  18.  
  19. Remove the brake booster mounting nuts.
  20.  
  21. Slide brake booster forward enough to gain access to and remove clutch master cylinder.
  22.  
  23. Remove clutch master cylinder reservoir.
  24.  
  25. Disconnect clutch master cylinder rod from clutch pedal. Inspect plastic retainer. If retainer is broken or damaged in any way, it MUST be replaced upon reassembly.
  26.  
  27. Remove two clutch master cylinder retaining nuts.
  28.  
  29. Remove the self-docking connector bracket.
    WARNING
    Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly.

  30.  
  31. Remove master cylinder from mounting position and carefully work hydraulic pipe from out of engine compartment. If necessary, unfasten ABS module and purge solenoid assembly to gain necessary clearance. If difficulty is encountered in removing system from vehicle, cut master cylinder hydraulic tube to divide system into two pieces.
  32.  

To install:

  1. Install the master cylinder into position on the firewall. Route the hydraulic tube under hood as noted upon removal.
  2.  
  3. Install the self-docking connector bracket.
  4.  
  5. Install the master cylinder retaining nuts onto the master cylinder studs. Tighten the nuts to 100 inch lbs. (11 Nm).
  6.  
  7. Install the master cylinder remote reservoir onto the firewall.
  8.  
  9. Install the reservoir retaining screws. Tighten the screws to 100 inch lbs. (11 Nm).
  10.  
  11. Install the brake booster.
    WARNING
    Inspect the clutch master cylinder push rod plastic retainer for damage. If it is damaged (broken/cracked), it MUST be replaced.

  12.  
  13. Raise vehicle on hoist.
  14.  
  15. If master cylinder is being replaced also install a replacement slave cylinder. If master cylinder is being re-used then the slave cylinder may also be re-used (assuming both cylinders are in proper working order).

    Click image to see an enlarged view

    Fig. Clutch slave cylinder (1) and bracket (2) at transaxle-2.0L models

    Clutch slave cylinder (1) and bracket (2) at transaxle-2.0L models
  16.  
  17. If master cylinder is being replaced, connect the master cylinder hydraulic line to the replacement slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line.
  18.  
  19. Lower vehicle.
  20.  
  21. Loosen the push rod adjustment screw.

    Click image to see an enlarged view

    Fig. Clutch master cylinder pushrod adjusting screw (1)

    Clutch master cylinder pushrod adjusting screw (1)
  22.  
  23. Install the push rod onto the pedal pin.
  24.  
  25. Gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 55 inch lbs. (6 Nm).
  26.  
  27. Install the ABS module/purge solenoid, PDC, and air cleaner.
  28.  
  29. Depress and release the clutch pedal a minimum of ten (10) times to allow any residual air in the system to be vented to the reservoir. If residual air becomes trapped in the system, bleed the clutch hydraulic system as described later in this section.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Top off clutch master cylinder reservoir with DOT 3 brake fluid.
  34.  
  35. Verify correct clutch operation.
  36.  

2.4L Turbo Engines

NOTE
Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the slave cylinder assembly.

  1. Remove air cleaner assembly.
  2.  
  3. Disconnect battery negative cable.
  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Using Tool 6638A, disconnect clutch hydraulic quick-connect fitting.

    Click image to see an enlarged view

    Fig. Disconnecting quick connect fitting (1) using tool 6638A (2)

    Disconnecting quick connect fitting (1) using tool 6638A (2)
  8.  
  9. Remove hydraulic hose from left rail retainers.

    Click image to see an enlarged view

    Fig. Master cylinder (1), reservoir (2), retainer clips (3) and (4)

    Master cylinder (1), reservoir (2), retainer clips (3) and (4)
  10.  
  11. Lower vehicle.
  12.  
  13. Remove PDC bracket and position out of way.
  14.  
  15. Remove lower instrument panel bezel.
  16.  
  17. Remove clip and disconnect the brake booster input rod from the brake pedal pin.

    Click image to see an enlarged view

    Fig. Clip (1) and brake booster mounting nuts (2) and (3)

    Clip (1) and brake booster mounting nuts (2) and (3)
  18.  
  19. Remove the brake booster mounting nuts.
  20.  
  21. Slide brake booster forward enough to gain access to and remove clutch master cylinder.
  22.  
  23. Remove clutch master cylinder reservoir.
  24.  
  25. Disconnect clutch master cylinder rod from clutch pedal. Inspect plastic retainer. If retainer is broken or damaged in any way, it MUST be replaced.
  26.  
  27. Remove two clutch master cylinder retaining nuts.
  28.  
  29. Remove the self-docking connector bracket.
    WARNING
    Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly.

  30.  
  31. Remove master cylinder from mounting position and carefully work hydraulic pipe from out of engine compartment. If necessary, unfasten ABS module and purge solenoid assembly to gain necessary clearance.
  32.  

To install:

  1. Install the master cylinder into position on the firewall.
  2.  
  3. Install the self-docking connector bracket.
  4.  
  5. Install the master cylinder retaining nuts onto the master cylinder studs. Tighten the nuts to 100 inch lbs. (11 Nm).
  6.  
  7. Route the hydraulic tube as noted upon removal.
  8.  
  9. Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line.
  10.  
  11. Install the master cylinder remote reservoir onto the firewall.
  12.  
  13. Install the reservoir retaining screws. Tighten the screws to 100 inch lbs. (11 Nm).
  14.  
  15. Install the brake booster.
    WARNING
    Inspect the clutch master cylinder push rod plastic retainer for damage. If it is damaged (broken/cracked), it MUST be replaced.

  16.  
  17. Loosen the push rod adjustment screw.

    Click image to see an enlarged view

    Fig. Clutch master cylinder pushrod adjusting screw (1)

    Clutch master cylinder pushrod adjusting screw (1)
  18.  
  19. Install the push rod onto the pedal pin.
  20.  
  21. Gently lift clutch pedal upward until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 55 inch lbs. (6 Nm).
  22.  
  23. Install the ABS module/purge solenoid, PDC, and air cleaner.
  24.  
  25. Depress and release the clutch pedal a minimum of ten (10) times to allow any residual air in the system to be vented to the reservoir. If residual air becomes trapped in the system, bleed the clutch hydraulic system as described later in this section.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Top off clutch master cylinder reservoir with DOT 3 brake fluid.
  30.  
  31. Verify correct clutch operation.
  32.  

 
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