Toyota Tercel 1984-1994 Repair Guide

Clutch Release Cylinder

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REMOVAL & INSTALLATION




CAUTION
On models equipped with a Supplemental Restraint System (SRS) or "air bag,'' work must NOT be started until at least 90 seconds have passed from the time that both the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery.

Do not spill brake fluid on the painted surfaces of the vehicle. If this occurs, wash it off immediately using plenty of clean water.

  1. Disconnect the negative battery cable.
  2.  
  3. Using a flare nut or line wrench, disconnect the hydraulic line on the clutch release from it's master cylinder. Use a container to catch the fluid.
  4.  
  5. Remove the release cylinder retaining nuts/bolts, then remove the cylinder.
  6.  

To install:
  1. Install the cylinder to the clutch housing, then tighten the bolts to 9 ft. lbs. (12 Nm).
  2.  
  3. Connect the hydraulic line.
  4.  
  5. Bleed the system and remember to top up the fluid in the clutch master cylinder when finished.
  6.  

OVERHAUL



See Figure 1

Refer to the exploded view of the release cylinder and components as a guide for the overhaul procedure.

  1. Remove the pushrod assembly and the rubber boot.
  2.  
  3. Withdraw the piston, complete with its cup; don't separate the cup from the piston unless it is being replaced.
  4.  
  5. Wash all the parts in brake fluid.
  6.  
  7. Replace any worn or damaged parts. Inspect the cylinder bore carefully for any sign of damage, wear or corrosion.
  8.  

To assemble:
  1. Before reassembly, coat all internal parts in clean brake fluid. Insert the spring and piston into the cylinder.
  2.  
  3. Install the boot and insert the pushrod.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the release cylinder components

 
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