Clutch hydraulic release system – removal and installation

Removal

Note: The clutch hydraulic release system is serviced as an assembly. The components cannot be serviced separately. They’re filled with fluid during manufacture, then sealed. They must not be disassembled or discon­nected. If the system is leaking or has air in it, replace the entire assembly.

1. Raise the vehicle and support it securely on jackstands.

2. Remove the fasteners attaching the release cylinder to the clutch housing, then separate the release cylinder from the clutch housing.

3. Disengage the clutch hydraulic fluid line from the retaining clip and stud on the firewall.

4. Lower the vehicle.

5. Pry off the retainer clip from the pushrod-to-clutch pedal pin, then slide the pushrod off the pin. Remove the pin bushing and inspect it. If it’s worn, replace it.

6. Unplug the electrical connector for the clutch pedal position switch, then remove the clutch master cylinder mounting fasteners.

7. To avoid spillage, make sure that the cap on the master cylinder’s remote reservoir is tight, then remove the reservoir mounting fasteners. Caution: Brake fluid will damage paint. If any is accidentally spilled, wash it off with water.

8. Detach the master cylinder from the firewall, then carefully lift the system from the vehicle.

Installation

Caution: If you’re installing a new clutch hydraulic release system, you’ll notice a ship­ping stop on the master cylinder pushrod. DO NOT remove this shipping stop until after the clutch release cylinder has been installed, but DO remove it BEFORE the clutch is oper­ated.

Note: The new clutch hydraulic system comes as two pieces to ease installation. After con­necting the hydraulic line to the release cylin­der, the line should not be disconnected.

9. Carefully maneuver the clutch hydraulic release system assembly into position.

10. Insert the clutch master cylinder in the firewall. Install the nuts and tighten them to the torque listed in this Chapter’s Specifications.

11. Install the remote reservoir and tighten the fasteners securely.

12. Install the bushing on the pushrod-to­clutch pedal pivot pin. Use a new bushing, if necessary.

13. install the master cylinder pushrod on the pin. Secure the rod with the retainer clip. Use a new clip if the old one is weak.

14. Plug in the electrical connector for the clutch pedal position switch.

15. Raise the vehicle and support it securely on jackstands.

16. Attach the clutch fluid hydraulic line to the retaining clip and stud on the firewall.

17. Install the release cylinder. Make sure the cap at the end of the cylinder rod is seated properly in the release fork.

18. Install the release cylinder mounting fasteners and tighten them securely. If a new clutch hydraulic release system has been installed, connect the hydraulic line to the release cylinder.

19. Remove the jackstands and lower the vehicle.

20. If a new clutch hydraulic release system has been installed, remove the plastic ship­ping stop from the master cylinder pushrod before operating the clutch.

21. Test drive the vehicle and make sure the clutch hydraulic release system is operating properly.