Prior to any vehicle service that requires removal of the slave cylinder, the master cylinder pushrod must be disconnected from the clutch pedal. If it is not disconnected, permanent damage to the slave cylinder will occur if the clutch pedal is depressed while the slave cylinder is disconnected.
REMOVAL & INSTALLATION
- Disconnect the negative (-) battery cable.
- Disconnect and plug the hydraulic line at the slave cylinder.
- Remove the slave cylinder-to-bracket bolts, and remove the slave cylinder.
- Place the slave cylinder at the mounting bracket and position the cylinder pushrod into the clutch release lever.
- Install the slave cylinder-to-bracket nuts and tighten them to 16 ft. lbs. (22 Nm).
- Install the hydraulic line to the slave cylinder and tighten it to 13 ft. lbs. (17 Nm).
- Fill the clutch master cylinder with the recommended brake fluid and bleed the system as follows.
CLUTCH SYSTEM BLEEDING
When the hydraulic portion of the clutch system has been opened, air enters the system and has to be removed before proper operation can be restored. Use the following procedures to bleed the clutch hydraulic system.
- Fill the fluid reservoir directly from a can of unused Delco Supreme No. 11 brake fluid or equivalent. Do not use the old fluid because old fluid is contaminated with moisture and dirt which may damage the hydraulic system.
Make sure the fluid reservoir is kept full of fluid. If not, air will be pulled into the system when the reservoir runs out of fluid.
- Remove the floor mat or any other object that may obstruct the full stroke of the clutch pedal.
- Unscrew the bleeder screw at the slave cylinder enough to allow fluid to be pumped out ( 1 / 2 -1 full turn).
- Push the clutch pedal down through the full stroke.
- Have an assistant close the bleeder while the pedal is still fully extended. Allow the pedal to return quickly to its stop (with the bleeder Closed).
- Repeat this procedure until no air bubbles can be seen in the fluid.
It is extremely important that cleanliness be maintained throughout the bleeding operation.
- Remove the slave cylinder from the vehicle as outlined in the previous section.
- Pull the dust cover back and remove the circlip together with the retaining ring and pushrod.
- Shake the cylinder to remove the piston and seal.
- Replace all serviceable seals and parts. Clean the remaining parts thoroughly with denatured alcohol and place them on a clean piece of paper. Examine the bore of the cylinder for visible signs of scores and ridges. If these conditions are excessive, the cylinder will have to be replaced.
- Lubricate the seal and piston bore with unused DOT 3 brake fluid and insert the seal and piston assembly into the cylinder.
- Install the pushrod and secure with the circlip.
- Coat the inside of the dust cover with Silicone Lubricant No. 5459912 or equivalent. Install the dust cover onto the cylinder housing end.
- Remount the slave cylinder on the vehicle and bleed the system as outlined in the "Clutch System Bleeding" procedures in this section.