Volvo 240/740/760/780/940/960 1990-1998

Master Cylinder

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On some models, the brake master cylinder incorporates the clutch master cylinder. For those models, refer to Brake Master Cylinder removal and installation in Brakes .

REMOVAL & INSTALLATION



See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the clutch reservoir with a bulb syringe.
  4.  


WARNING
Be careful not to drip brake fluid on any painted surfaces.

  1. Remove the underdash panel and remove the lockring and pin from the clutch pedal.
  2.  
  3. Remove the hose from the master cylinder. Use a clean jar to collect spillage.
  4.  
  5. Unfasten the retaining bolts and remove the master cylinder.
  6.  

To install:

When reinstalling, make sure that the clearance (free-play) between the pushrod and piston is 0.04 inch (1mm).

  1. Install the master cylinder and tighten the retaining bolts.
  2.  
  3. Install the hose onto the master cylinder. Make certain the hose is correctly threaded and secure.
  4.  
  5. Install the pushrod onto the pedal.
  6.  
  7. Top up the fluid and bleed the system as explained later in this section.
  8.  
  9. Connect the negative battery cable.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the hydraulic clutch system

 
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