Clutch Master Cylinder

Clutch Master Cylinder Components 1. Pin
2. Cotter pin
3. Clevis
4. Locknut
5. Corolla models, produced from 1996
6. Dust boot
7. Split retaining ring
8. Washer
9. Corolla models, produced 1993-1995
10. Stop ring
11. Gasket
12. Pushrod
13. Piston
14. Cylinder
15. Spring pin with hole
16. Bushing
17. Reservoir
18. Float
19. Cap

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* Before starting work, find out the cost of a rebuilt or new cylinder and whether they are available. Depending on this, decide whether it is worthwhile to rebuild the cylinder yourself. If you decide to rebuild the cylinder yourself, check its internal bore before purchasing parts, as described in step 7.

Removal

PROCEDURE
1. Disconnect the negative battery cable.

* If your vehicle's stereo has an anti-theft code system, make sure you know the radio activation code before disconnecting the battery.

2. Under the instrument panel, disconnect the pushrod from the clutch pedal. It is retained by a pin with a cotter pin. To remove the pin, remove the cotter pin (indicated by arrow).
3. Disconnect the hydraulic line from the clutch master cylinder. If equipped, use a flare nut wrench when loosening the connection to avoid rounding the flats. Prepare several rags, as some hydraulic fluid may spill when the line is disconnected.

* Make sure hydraulic fluid does not contact the vehicle paint, as it will damage the paint.

4. Under the instrument panel, remove the nuts securing the clutch master cylinder to the bulkhead. Remove the master cylinder, taking care not to spill hydraulic fluid.

Bulkhead

PROCEDURE
1. Remove the reservoir cap and drain the brake fluid from the master cylinder. Using a hammer and punch, remove the spring pin (see illustration Master Cylinder Components, clutch release system), then carefully remove the reservoir.
2. On Corolla models produced up to 1995, use a small screwdriver to raise the tab of the retaining ring so that it is flush with the ring surface. Then remove the retaining ring, gasket and pushrod from the cylinder.
3. On Corolla models produced from 1996, remove the dust boot, press down on the piston and remove the split retaining ring using pliers. Remove the pushrod and washer.
4. Turn the cylinder over and tap it on a block of wood to remove the piston.

* If the new cylinder is supplied already assembled, skip the steps describing operations that do not need to be performed.

5. Remove the spring from the piston.
6. Carefully remove the seal from the piston.
7. Inspect the inner surface of the cylinder for deep scratches or nicks. The surface should feel smooth. If it is not perfectly smooth, replace the master cylinder with a new or remanufactured one.
8. If using a remanufactured cylinder, also install the new parts supplied with it and follow any instructions provided. Before installation, wash all parts in brake system cleaning fluid, alcohol or clean brake fluid. Do not use gasoline-based solvents.
9. Install the seal on the piston. The lips of the seal must face away from the pushrod.
10. Install the spring on the other end of the piston.
11. Generously lubricate the inner surface of the cylinder and the seal with brake fluid.
12. Carefully insert the piston into the cylinder, taking care not to damage the seal. When installing, insert the end of the piston on which the spring is fitted first, so that the end of the piston to which the pushrod attaches is closer to the open end of the cylinder.
13. On Corolla models produced up to 1995, install the pushrod and a new gasket into the cylinder, compress the spring and install a new retaining ring. On Corolla models produced from 1996, install the pushrod and washer, press on the pushrod and install a new split retaining ring, making sure it seats fully in its groove. Install a new dust boot.
14. Install the reservoir, replacing the bushing. Insert the spring pin using a hammer and punch. Check that it protrudes no more than 3.175 mm on both sides of the reservoir.

Installation

PROCEDURE
1. Install the master cylinder on the bulkhead, tightening the mounting nuts by hand.
2. Connect the hydraulic line to the master cylinder, moving the cylinder slightly if necessary. Do not cross-thread the connection.
3. Tighten the mounting nuts and the hydraulic line fitting.
4. Install the pushrod on the clutch pedal.
5. Fill the clutch master cylinder reservoir with fresh hydraulic fluid (see Subsection 2.1), then bleed the clutch hydraulic system (see Subsection 8.2.5).
6. Check clutch pedal installation and free play (see Subsection 8.2).