Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Clutch Master Cylinder

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See Figure 1

Only the Sidekick Sport utilizes a hydraulic clutch actuation system.



Click image to see an enlarged view

Fig. Fig. 1: Hydraulic clutch system component locations-Sidekick Sport models only

REMOVAL & INSTALLATION



See Figure 2

  1. Open the hood.
  2.  
  3. Wipe all of the dirt off the master cylinder reservoir and cap, then siphon the clutch fluid out of the master cylinder with a syringe.
  4.  
  5. From inside the vehicle, remove the pushrod clevis pin, connecting the master cylinder pushrod to the clutch pedal.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the clutch master cylinder mounting

  1. Loosen the clutch fluid line fitting, then detach the line from the master cylinder.
  2.  


WARNING
Do not allow the clutch fluid to come into contact with painted surfaces; if it does, wash the fluid off immediately.

  1. Loosen the mounting nuts, then remove the master cylinder and gasket from the firewall.
  2.  

To install:
  1. To bleed air from the master cylinder, tilt the master cylinder approximately 15 degrees off of vertical, then add fluid to the reservoir. Plug the brake line fitting hole in the master cylinder immediately after bleeding the air from it.
  2.  
  3. Install the master cylinder and a new gasket on the firewall.
  4.  
  5. Install and tighten the mounting nuts to 115 inch lbs. (13 Nm).
  6.  
  7. Install and tighten the brake fluid line fitting to 142 inch lbs. (16 Nm).
  8.  
  9. Reattach the master cylinder pushrod to the clutch pedal, then install the pushrod clevis pin.
  10.  
  11. Fill the master cylinder fluid reservoir to the maximum level.
  12.  
  13. Bleed all residual air from the hydraulic system.
  14.  

 
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