Clutch Cylinder Installation

Ⅰ.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 necessay to disconnect bttery,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 counterclockwise and remove.

NOTE:some vehicles require clockwise rotation to remove.

6.Repeat process in reverse order to install replacement cylinder.

7.With reservoir lid removed and reservoir filled,depress the clutch pedal with short quick strokes 10-20 times or until pedal is firm.Then depress pedal and hold it down.Open the bleed screw on the cylinder,if so equipped,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.

Bleed screw torque of Plastic cyl(3 to 5 Nm);Aluminum cyl(15 to 20 Nm)

Tips:

√Be sure fluid supply and/or pressure lines are not kinked.

√Be sure pushrod 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-connect o-rings for cracking,splitting or contamination and replace if necessary.

Ⅱ.EXTERNAL CLUTCH SLAVE CYLINDER INSTALLATION

NOTE: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 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.Install slave cylinder on vehicle and replace lid on reservoir.Using short quick 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 short quick 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.

Ⅲ.CONCENTRIC CLUTCH SLAVE CYLINDER INSTALLATION

NOTE:Replacing the concentric slave cylinder requires the transmission to be removed and reinstalled.Consult vehicle service manual for proper procedures.

1.Carefully clean of the hydraulic tube coupling.Disconnect the hydraulic tube coupling at thetransmisson with the hyaraulicline Quick Connect tool by sliding the white plastic sleeve toward theslave cylinder.

2.Remove the transmission per your vehicle manufacturer's Shop Manual.

3.Remove the concentric slave cylinder mounting bolts and remove from the transmission.

4.Clean the transmission input shaft and install the new concentric slave cylinder.Make sure the slave cylinder is installed fat against the transmission mounting surface.

5.Install the slave cylinder attaching bolts and tighten per the vehicle manufacturer Shop Manual requirements.Check to make sure the slave cylinder is not cocked.

? Plastic(torque 3 to 5 Nm);Aluminum(15 to 20 Nm)

6.Reinstall the transmission per your vehicle manufacturers Shop Manual.

7.Inspect the hydraulic tube coupling for damage and contamination,replace the O ring and lube with clutch hydraulic fluid.

8.Reconnect the hydraulic tube by inserting the male coupling into the female coupling on the concentric slave cylinder.Make sure the coupling is secure (by pulling both ends).

9.Carefully clean the top and sides of the master cylinder reservoir before opening to prevent contamination of the system with dirt,water,and other foreign material.

10.Remove the reservoir cap and diaphragm when checking or adding fluid.

11.Fill the reservoir with new clutch hydraulic fluid or an approved DOT 3 brake fluid.

12.Pump the clutch pedal 15-20 times,making sure that the pedal is allowed to return completely after each stroke.

NOTE:During step #12 the concentric slave cylinder will fill with clutch fluid and the release bearing will begin to move.Continued pedal strokes will bleed the system of all air and the release bearing will move through its entire stroke with each pedal application.

13.Depress the clutch pedal and hold it down.

14.Using the socket wrench set,slowly open the bleed screw located on the concentric slave cylinder and allow any trapped air to escape.Fluid will emerge from the CSC bleed port.

When it is a solid stream,close the port.

15.Torque the bleed screw quickly and release the clutch pedal . Do not over tighten bleed screw.Bleed screw of Plastic CSC (torque 3 to 5 Nm)

Bleed screw of Aluminum CSC(15 to 20 Nm)

16.If clutch engagement is not satisfactory,repeat steps 11 to 14 until all the air is removed and bubbles no longer appear in reservoir.

17.Reinstall diaphragm and reservoir cap.

NOTES:

◆ Under normal usage,small amounts of air remaining will be purged from the system.

◆ The clutch release bearing for this concentric slave cylinder is designed to operate without lubrication on the bearing housing bore.If bearing assembly,bearing housing or slave cylinder hydraulic piston bore are lubricated,seals may fail prematurely.

BLEEDING TIPS

◆ Use only new brake fluid that meets DOT-3 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

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