Clutch Master Cylinder Replacement
NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or plastic, wash it off immediately with water.
  • The illustrations show LHD model except where the procedure is defferent for RHD model.
  1. Remove the brake fluid from the clutch master cylinder reservoir with a syringe or other suitable device.
  1. Remove the clutch master cylinder reservoir (A).
LHD model
RHD model
  1. Disconnect the clutch line (A) from the clutch master cylinder (B). To prevent spills, cover the line joint with rags or shop towels.
    NOTE: Loosen the flare nut (C) while holding the clutch line connector (D) with a wrench.
  1. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke. Remove the master cylinder mounting nuts (C).
  1. Remove the clutch master cylinder (A) and the master cylinder seal (B).
  1. Remove the reservoir hose (C).
    NOTE: Inspect the hose. If the hose has damage, leaks, interference, or twisting, replace it.
  1. Remove the retaining clip (A), then remove the clutch line connector (B), the O-ring (C) from the master cylinder (D).
  1. Install the clutch line connector (A) with a new O-ring (B), then set in a new retaining clip (C) to the master cylinder (D).
    NOTE: Apply the rubber grease on the O-ring and the joint part (E) of the clutch line connector.
  1. To prevent the retaining clip (A) from coming off, pry apart the tip (B) of the retaining clip with a screwdriver.
  1. Install the reservoir hose and adjust the hose clamp (A) positions and its direction.
    NOTE: When attaching the reservoir hose, align the yellow mark on the hose to the rib on reservoir connection area, and the blue mark on the hose to rid on the clutch master cylinder connection area.
  1. Install a new master cylinder seal (A) and the clutch master cylinder (B).
  1. Install the master cylinder mounting nuts (A).
  1. Apply multipurpose grease to the pedal pin (B), and mating surfaces (C) of the yoke and the pedal. Slide the pedal pin into the yoke, then install a lock pin (D).
  1. Connect the clutch line (A) to the clutch master cylinder (B).
    NOTE: Tighten the flare nut (C) while holding the clutch line connector (D) with a wrench.
  1. Install the clutch master cylinder reservoir (A).
  1. Check the clutch operation, and check for leaks.
  1. Test-drive the vehicle.
LHD model
RHD model