Clutch release slave cylinder (Hyundai Sonata EF)

Contents: Removal ⇓ Disassembly ⇓ Examination ⇓ Assembly ⇓ Installation ⇓

Clutch release drive slave cylinder.

1 - valve plunger, 2 - valve spring, 3 - working cylinder body, 4 - return spring, 5 - piston, 6 - boot, 7 - rod, 8 - pin, 9 - cotter pin, 10 - clutch hydraulic tube.

Removal

1. Disconnect the clutch release hydraulic hose.

2. Disconnect the slave cylinder rod fork from the clutch release lever.

3. Unscrew the two bolts, remove the washers and the clutch release drive slave cylinder.

Disassembly

1. Remove the clutch hydraulic hose, valve plunger, spring, rod and boot.

2. Remove all contaminants from the inner surface of the working cylinder.

3. Remove the piston from the working cylinder using compressed air.

Attention:

Wrap the slave cylinder with a rag to prevent the piston from flying out during removal and to prevent injury.

Apply compressed air gradually to prevent the working fluid from splashing and getting into your eyes or on your skin.

Examination

1. Check the clutch release slave cylinder for fluid leaks.

2. Check the slave cylinder housing for damage.

3. Check the inner surface of the working cylinder body for rust and damage.

5. Measure the inner diameter of the working cylinder using a bore gauge.

Note: After installing the bore gauge in the working cylinder, measure the diameter in three sections, moving the bore gauge in the axial direction. Then turn the bore gauge by 90° and repeat the operation. All six obtained values must satisfy the technical data.

Nominal value: 20.64 mm

6. Measure the outside diameter of the piston using a micrometer and calculate the clearance between the piston and the working cylinder body (the difference between the inside diameter of the working cylinder and the outside diameter of the piston).

If the gap exceeds the maximum permissible value, replace the slave cylinder assembly.

[The original can be found on the resource: hyundaibook]

Maximum permissible value: 0.15 mm

Assembly

1. Apply brake fluid to the inner surface of the clutch release actuator slave cylinder housing and to the outer surface of the piston. Install the piston assembly into the slave cylinder housing.