REMOVAL & INSTALLATION
1986-88 Only (D21-D Series)
- Loosen the union nuts and disconnect the two hydraulic lines at the damper.
- Remove the mounting bolts and then remove the clutch damper from the firewall.
- Install the damper and tighten the bolts to 6-8 ft. lbs. (8-11 Nm).
- Reconnect the hydraulic lines being careful not to damage the union nuts.
- Bleed the system.
See Figure 1
- Remove the damper cover and gasket from the cylinder body.
- Remove the rubber damper, piston and cups and spring from the cylinder.
- Clean the inside of the cylinder with a rag and inspect for scoring. If there is no serious damage, hone the cylinder just enough to remove deposits. Replace the cylinder if light honing does not remove the score marks. Wash all the parts in brake fluid before assembly.
- Coat the new rubber parts in brake fluid and reassemble. Coat the piston with lithium soap based glycol grease.
- Install a new gasket and tighten the damper cover to 3-4 ft. lbs. (3-5 Nm).
BLEEDING THE CLUTCH HYDRAULIC SYSTEM
See Figure 2
This procedure may be utilized when either the clutch master or release cylinder has been removed or if any of the hydraulic lines have been disturbed.
- Fill the master cylinder reservoir with brake fluid.
On 1986-88 models that incorporate a clutch damper in the hydraulic system, perform Steps 1-10 for the clutch damper and then move on to the release cylinder.
- Remove the cap and loosen the bleeder screw on the clutch release cylinder. Cover the hole with your finger.
- Have an assistant pump the clutch pedal several times. Take your finger off the hole while the pedal is being depressed so that the air in the system can be released. Put your finger back on the hole and release the pedal.
- After fluid pressure can be felt (with your finger) tighten the bleeder screw.
- Put a short length of hose over the bleeder screw and place the other end into a jar half full of clean brake fluid.
- Depress the clutch pedal and loosen the bleeder screw. Allow the fluid to flow into the jar.
- Tighten the plug and then release the clutch pedal.
- Repeat Steps 6-7 until no air bubbles are visible in the bleeder tube.
- When there are no more air bubbles in the system, tighten the plug fully with the pedal depressed. Replace the plastic cap.
- Fill the master cylinder to the correct level with brake fluid.
- Check the system for leaks.