Removal
1. Disconnect the cable from the negative battery terminal.
2. Under the front panel, disconnect the push rod from the upper end of the clutch pedal. It is secured with a cotter pin (see illustration).
6.2. Master cylinder mounting parts. 1. Cotter pin, 2. Washer, 3. Axle
3. Disconnect the hydraulic line from the clutch master cylinder. If possible, use a cone nut wrench to avoid rounding the nipple. Keep a rag handy as some fluid will leak out when you disconnect the line.
Caution: Avoid contact of brake fluid with paintwork to avoid damage.
4. Under the front panel, unscrew the nut securing the master cylinder to the cross-partition. Remove the master cylinder, again being careful not to spill any fluid.
Bulkhead
5. Remove the reservoir cap and drain all the fluid from the master cylinder. Unscrew the clamp bolt installed inside the reservoir, then remove the reservoir from the cylinder body.
6. Remove the rubber boot from the plunger, then remove the spring ring.
6.6. Exploded view of a typical master cylinder. 1. Spring ring, 2. Pusher, 3. Cover, 4. Piston, 5. Tank cover, 6. Clamp, 7. Tank, 8. Master cylinder body
7. Remove the pusher from the cylinder.
8. To remove the piston, tap the cylinder on a wooden block.
Note: If the repair kit includes a piston assembly, skip steps 9.11 and 14.
9. Separate the spring from the piston.
10. Remove the spring stop, seal and adjusting lining from the push rod.
11. Carefully remove the cuff from the piston.
12. Inspect the inside surface of the master cylinder for deep scratches, burrs, and pitting. The surface should feel smooth. If the surface is not smooth, replace the cylinder with a new one.
13. When reassembling the cylinder, use new parts from the repair kit and follow the instructions included with the kit. Before reassembling, wash all parts in brake cleaner, denatured alcohol or clean brake fluid. Do not use gasoline-based solvents.
14. Install the cuff on the piston. The edges of the cuff should be facing away from the pusher.
15. Install the adjusting shim, spring stop and spring on the other end of the piston.
16. Lubricate the inside surface of the cylinder and seals with clean brake fluid (DOT 3).
17. Carefully insert the piston assembly into the cylinder, being careful not to damage the seals. The piston is inserted with the end on which the spring is mounted, and the end of the piston that connects to the pusher should be located closer to the hole.
18. Install the push rod and lock washer into the cylinder, compress the spring and install a new spring washer.
19. Apply Girting Rubber Grease or similar grease to the dust boot and install the boot onto the master cylinder.
Installation
20. Install the master cylinder onto the cross member by tightening the nuts with your fingers.
21. Connect the hydraulic tube to the master cylinder, moving the cylinder slightly if necessary to align the threads. Do not tighten the fitting.
22. Tighten the mounting nuts to the required torque, then tighten the hydraulic tube nipple.
23. In the passenger compartment, connect the push rod to the clutch pedal.
24. Fill the clutch master cylinder reservoir with DOT 3 specification brake fluid and bleed the clutch system as described in section 8.