REMOVAL & INSTALLATION
- Remove the slave cylinder attaching bolts and the pushrod from the shift fork.
- Disconnect the flexible fluid hose from the slave cylinder and remove the unit from the vehicle.
- Install the slave cylinder in the reverse order of removal and bleed the clutch hydraulic system.
- Remove the slave cylinder from the vehicle.
- Remove the pushrod and boot.
- Force out the piston by blowing compressed air into the slave cylinder at the hose connection.
- Clean all of the parts in clean brake fluid.
- Check and replace the slave cylinder bore and piston if wear or severe scoring exists. Light scoring and glaze can be removed with crocus cloth soaked in brake fluid.
- Normally the piston cup should be replaced when the slave cylinder is disassembled. Check the piston cup and replace it if it is found to be worn, fatigued or scored.
- Replace the rubber boot if it is cracked or broken.
- Lubricate all of the new parts in clean brake fluid and reassemble in the reverse order of disassembly, taking note of the following:
- Use care when reassembling the piston cup to prevent damaging the lipped portion of the piston cup.
- Fill the master cylinder with brake fluid and bleed the clutch hydraulic system.
- Adjust the clearance between the pushrod and the shift fork to 5 / 64 ".
BLEEDING THE CLUTCH HYDRAULIC SYSTEM
- Check and fill the clutch fluid reservoir to the specified level as necessary. During the bleeding process, continue to check and replenish the reservoir to prevent the fluid level from getting lower than 1 / 2 the specified level.
- Remove the dust cap from the bleeder screw on the clutch slave cylinder and connect a tube to the bleeder screw and insert the other end of the tube into a clean glass or metal container.
Take precautionary measures to prevent the brake fluid from getting on any painted surfaces.
- Pump the clutch pedal SLOWLY several times, hold it down and loosen the bleeder screw.
- Tighten the bleeder screw and release the clutch pedal gradually. Repeat this operation until air bubbles disappear from the brake fluid being expelled out through the bleeder screw.
- Repeat until all evidence of air bubbles completely disappears from the brake fluid being pumped out through the tube.
- When the air is completely removed, securely tighten the bleeder screw and replace the dust cap.
- Check and refill the master cylinder reservoir as necessary.
- Depress the clutch pedal several times to check the operation of the clutch and check for leaks.