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/CLUTCH MASTER CYLINDER EXTERNAL CLUTCH SLAVE CYLINDER INSTALLATION.pdf
Important Always refer to vehicle specific service manual for exact removal installation detail 9999923 rev 1 CLUTCH MASTER CYLINDER INSTALLATION 1 Disconnect pushrod from pedal Replace eyelet bushing if broken during removal 2 Remove interlock switch if attached from the pushrod 3 In some applications it may be necessary to disconnect battery reposition components and or remove inner fender to gain access to the clutch master cylinder 4 Disconnect line fitting or drive out retaining pin holding hydraulic line to cylinder If vehicle uses quick connect coupling in line clean and uncouple using the proper disconnect tool 5 Remove mounting bolts nuts For Twist and Lock type rotate cylinder about 45 degrees clockwise and remove NOTE some vehicles require counterclockwise rotation to remove 6 Bench bleed new cylinder before installing Block port fill reservoir with DOT3 fluid with cap removed Using a blunt tool depress piston into cylinder slowly about 1 and slowly release Repeat until bubbles no longer appear in reservoir or piston becomes hard to depress 7 Repeat process in reverse order to install replacement cylinder 8 Follow slave cylinder bleeding instructions below EXTERNAL CLUTCH SLAVE CYLINDER INSTALLATION NOTE Some slave cylinders are shipped with a plastic pushrod retaining strap DO NOT CUT OR REMOVE this strap as the bands are designed to break during the first clutch application It then provides a non metallic end for the pushrod to prevent wear and noise 1 Disconnect line or drive out the pin that holds the hydraulic line to the cylinder Remove line If vehicle uses quick connect fittings use proper disconnect tool to uncouple 2 Remove bolts or retainer holding cylinder to transmission Remove cylinder 3 Push in new cylinder s pushrod to disconnect retaining bands if so equipped and allow pushrod to fully extend DO NOT CUT OR DISCARD RETAINING STRAP 4 Tip cylinder at about 45 degrees and pour DOT 3 brake fluid into hydraulic port until air is expelled Insert hydraulic line into port and carefully reconnect or drive in retaining pin 5 Cylinders without bleeder screw Hold slave cylinder vertically with pushrod facing down making sure that slave is lower than master cylinder Slowly depress pushrod into cylinder about an inch while watching the reservoir for air bubbles Repeat process until air bubbles no longer appear usually about 10 15 strokes With reservoir lid removed slowly depress pushrod in far enough to reconnect the bands of the retaining strap if so equipped Install slave cylinder on vehicle and replace lid on reservoir Using slow short strokes depress clutch pedal 10 20 times or until pedal is firm 6 Cylinders with bleeder screw Install slave cylinder on vehicle With reservoir lid removed and reservoir filled depress the clutch pedal with slow short strokes 10 20 times or until pedal is firm Then depress pedal and hold it down Open the bleed screw on the cylinder to allow air and fluid to escape Torque the bleed screw then release pedal do not overtighten bleed screw Repeat process until air is removed clutch pedal is firm and clutch engagement is satisfactory Maintain fluid level in reservoir during the bleeding process Step 5 may be used in difficult bleeding situations Bleed screw torque for Plastic cylinder 3 to 5 Nm Aluminum cylinder 15 to 20 Nm INSTALLATION TIPS BLEEDING TIPS Be sure fluid supply and or pressure lines are not kinked Be sure pedal rod does not bind or stick Lubricate at eyelet end Do not allow lines to be closer than 4 inches from exhaust manifold pipe steel lines 2 inches Check quick disconnect o rings for cracking splitting or contamination and replace if necessary Use only new brake fluid that meets DOT 3 or 4 specifications Brake fluid absorbs moisture keep container closed and do not reuse old fluid from the vehicle Use caution in handling brake fluid Prevent contact with skin face eyes and painted surfaces Use a container to catch fluid during bleeding process Prevent contact of any petroleum based fluid gas oil transmission or power steering fluid etc with hydraulic clutch system or brake fluid If a damper exists in the hydraulic line inlet and outlet ports must be vertical to properly bleed Quick Disconnect Tool
