Removal
1. Drain the working fluid through the bleed nipple.
4. Remove the clamp securing the tube to the gearbox.
Examination
Check the hose and tube for rust, pitting and scoring.
Disassembly
1. Remove the piston retaining ring.
2. Remove the pusher and piston.
Note: Do not damage the push rod or the surface of the clutch master cylinder that contacts the piston.
Examination
1. Check the inside of the cylinder body for rust, pitting or wear.
2. Check the piston seal for wear.
3. Check the piston for rust, pitting or wear.
4. Check the clutch hydraulic tube for damage.
5. Use a bore gauge to measure the inner diameter of the clutch master cylinder and a micrometer to measure the outer diameter of the piston.
Note: Measure the inner diameter of the clutch master cylinder in three sections (base, center and top) in two perpendicular directions.
6. If the clearance between the piston and cylinder exceeds the permissible value, replace the master cylinder and/or piston assembly.
Gap: 0.15 mm
Assembly
1. Before assembly, lubricate the piston and cylinder bore diameter with DOT3 or DOT4 clutch fluid.
2. Install the piston assembly into the cylinder.
3. Install the piston retaining ring.
4. Install the pusher.
5. Connect the hose to the clutch master cylinder housing.
Installation
1. Connect the tube to the clutch slave cylinder.
4. Connect the push rod to the clutch pedal.
5. Bleed the clutch hydraulic drive.