Subaru Forester 1998-05

Master Cylinder

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Overhaul



  1. Remove the straight pin and reservoir tank.
  2.  
  3. Remove the oil seal.
  4.  
  5. Move the cylinder boot backward.
  6.  
  7. Remove the snap ring.
    CAUTION
    Be careful when removing the snap ring to prevent the rod, washer, and piston and return spring from flying out.

  8.  
  9. If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, return spring and gasket, replace the faulty part.
  10.  
  11. Apply a coat of grease to the contacting surfaces of the push rod and piston before installation.
  12.  
  13. Assemble the master cylinder in the reverse order of disassembly.

    Click image to see an enlarged view

    Fig. Remove the oil seal from the master cylinder



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    Fig. Move the cylinder boot backward



    Click image to see an enlarged view

    Fig. Exploded view of the master cylinder

  14.  

Removal & Installation



  1. Thoroughly drain the fluid from the reservoir tank.
  2.  
  3. Remove the snap pin and clevis pin, and separate the push rod of the master cylinder from the clutch pedal.
  4.  
  5. Remove the air intake assembly.
  6.  
  7. Remove the intercooler, if equipped.
  8.  
  9. Remove the clutch pipe from the master cylinder.
  10.  
  11. Remove the master cylinder assembly.

    Click image to see an enlarged view

    Fig. Separate the push rod from the clutch pedal.



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    Fig. Location of the master cylinder in the engine compartment

  12.  

To install:

  1. Install the master cylinder to the body. Tighten the mounting bolts to 13 ft. lbs. (18 Nm).
  2.  
  3. Install the clutch pipe to the master cylinder. Tighten the nut to 11 ft. lbs. (15 Nm).
  4.  
  5. Apply multi-purpose grease to the clevis pin. Connect the push rod of the master cylinder to the clutch pedal. Insert the clevis pin and install the snap pin.
  6.  
  7. Bleed the clutch system. Refer to -Hydraulic System Bleeding- in this section.
  8.  
  9. Install the intercooler, if equipped.
  10.  
  11. Install the air intake assembly.
  12.  

 
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