Clutch Release Cylinder

Clutch Release Cylinder Components
1. Release cylinder
2. Spring
3. Piston
4. Pushrod
5. Boot

* Before starting work, find out the cost of a remanufactured 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, check its inner surface before buying replacement parts.

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. Raise the vehicle and support it on stands.

3. Disconnect the release cylinder hydraulic line. If available, use a flare nut wrench to loosen the fitting so as not to round off the flats (indicated by the left arrow). Then remove the two mounting bolts (indicated by the right arrows). Prepare several rags, as some brake fluid may spill when the line is disconnected.
4. Remove the release cylinder mounting bolts.
5. Remove the release cylinder.

Bulkhead

PROCEDURE
1. Remove the pushrod and boot (see illustration Release Cylinder Components).
2. Tap the cylinder on a wooden surface to remove the piston and seal. Remove the spring from the cylinder bore.
3. Carefully 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 release cylinder.
4. Using new parts from the repair kit, assemble the cylinder, thoroughly lubricating all components with fresh brake fluid before assembly. Check that the spring and seal are installed correctly.

Installation

PROCEDURE
1. Install the clutch release cylinder on the clutch housing. Make sure the pushrod engages the socket of the release fork.
2. Connect the hydraulic line to the release cylinder. Tighten the fitting.
3. Fill the clutch master cylinder reservoir with fresh hydraulic fluid of the specified type (see Subsection 2.1).
4. Bleed the hydraulic system (see Subsection 8.2.5).
5. Lower the vehicle and connect the negative battery cable.