Tucson 2006-2008

Master Cylinder

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Overhaul



Specific to:

Hyundai Tucson 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the piston stop ring.
  4.  
  5. Pull out the push rod and piston assembly.
  6.  
  7. Remove the reserve tank band, reserve tank cap, and reserve tank.
    1. Use care not to damage the master cylinder body and piston assembly.
    2.  
    3. Do not disassemble the piston assembly.

      Click image to see an enlarged view

      Fig. Removing the piston stop ring of the clutch master cylinder

    4.  

  8.  
  9. Check the inside of the cylinder body for rust, pitting, or scoring.
  10.  
  11. Check the piston cup for wear or distortion.
  12.  
  13. Check the piston for rust, pitting, or scoring.
  14.  
  15. Check to make sure the clutch line tube is not clogged or restricted in any way.
  16.  
  17. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.
    NOTE
    Measure the inside diameter of the master cylinder at 3 places (bottom, middle, and top) in a perpendicular direction.

  18.  
  19. If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly. Limit: 0.006 inch (0.15mm).

    Click image to see an enlarged view

    Fig. Using a cylinder gauge to measure the master cylinder inside diameter

  20.  
  21. Apply the specified fluid to the inner surface of the master cylinder body (A) and to the entire periphery of the piston assembly (B). Specified fluid: Brake fluid DOT 3 or DOT 4.
  22.  
  23. Install the piston assembly.
  24.  
  25. Install the piston snap ring.
  26.  
  27. Install the push rod assembly.

    Click image to see an enlarged view