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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.
  • Without cruise control: Clutch pedal adjusting bolt is substituted as clutch pedal position switch B.
  • Put on gloves to protect your hands.
  1. Secure the hood in the wide open position (support rod in the lower hole).
  1. Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
  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. LHD model: Remove the clutch pipe bracket bolts (A).
  1. LHD model: Remove the reservoir hose from two clips.

  1. Disconnect the reservoir hose (A), then remove the clutch line (B) from the clutch master cylinder (C). Plug or wrap the end of the reservoir hose and clutch line with a shop towel to prevent brake fluid from coming out.
    NOTE:
    • Loosen the flare nut (D) while holding the clutch line connector (E) with a wrench.
    • Inspect the hose. If the hose has damage, leaks interference, or twisting, replace it.
  1. Remove the clutch master cylinder seal (F) from the clutch master cylinder.

  1. Remove the retaining clip (A), then remove the clutch line connector (B) and 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 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 clip with a screwdriver.

  1. Install the new clutch master cylinder seal (A) to the clutch master cylinder (B).
  1. Connect the clutch line (C), and reservoir hose (D).
    NOTE: Tighten the flare nut (E) while holding the clutch line connector (F) with a wrench.
  1. LHD model: Install the two reservoir hose clips.

  1. LHD model: Install the clutch pipe bracket bolts (A).

  1. Make sure the hose clamps (A) are positioned on the master cylinder (B) and reservoir (C) as shown.
LHD model
RHD model

  1. Install the master cylinder mounting nuts (A).
  1. Apply multipurpose grease to the pedal pin (B), and slide it into the yoke, then install a lock pin (C).
  1. Check the clutch operation, and check for leaks.
  1. Test-drive the vehicle.