Clutch Master Cylinder Replacement LHD

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the clutch pedal assembly. Refer to Clutch Pedal Replacement.
4. Place the clutch pedal on a suitable work surface.




Important: Note the position of the clutch over centre spring (4).

5. Remove the clutch over centre spring (4).
6. Use a suitable screwdriver to pry off the push rod connector (1).
7. Disconnect the push rod connector (1) from the clutch pedal.
8. Remove the clutch master cylinder to clutch pedal retaining bolts (3).
9. Remove the clutch master cylinder (2).

1. Install the clutch master cylinder (2) to the pedal assembly (1).

Important: The clutch master cylinder to clutch pedal retaining bolts (1) must not to be fully tightened at this stage.

2. Install the clutch master cylinder to clutch pedal retaining bolts (1).

Do not fully tighten at this stage.

3. Connect the push rod connector (3) to the clutch pedal pin (4).
4. Remove the clutch position switch. Refer to Clutch Pedal Position Switch Replacement.

Important: Measure from pedal pad bottom edge when at the top of travel to mod plate surface plane.

5. With an assistant raise clutch pedal to a height of 224 mm (a) to achieve the correct pedal height.

Notice: Refer to Fastener Notice in the Preface section.

6. Tighten the clutch master cylinder to clutch pedal retaining bolts (1).

Tighten
Tighten the bolts to 12  N·m (106 lb in).





Important: Pushing the pedal to the bottom of travel will assist with the clutch over centre spring (1) installation.

Important: Make sure that the clutch over centre spring (1) is installed in its original position.

7. Install the clutch over centre spring (1).
8. Install the clutch position switch. Refer to Clutch Pedal Position Switch Replacement.
9. Install the clutch pedal assembly. Refer to Clutch Pedal Replacement.
10. Reconnect the clutch patch harness to the cockpit harness.
11. Enable the SIR system. Refer to SIR Disabling and Enabling.
12. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.
13. Road test vehicle for correct clutch operation.

Clutch Master Cylinder Replacement RHD

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the clutch pedal assembly. Refer to Clutch Pedal Replacement.
4. Place the clutch pedal on a suitable work surface.




Important: Note the position of the clutch over centre spring (4).

5. Remove the clutch over centre spring (4).
6. Use a suitable screwdriver to pry off the push rod connector (1).
7. Disconnect the push rod connector (1) from the clutch pedal.
8. Remove the clutch master cylinder to clutch pedal retaining bolts (3).
9. Remove the clutch master cylinder (2).

1. Install the clutch master cylinder (2) to the pedal assembly (1).

Important: The clutch master cylinder to clutch pedal retaining bolts (1) must not to be fully tightened at this stage.

2. Install the clutch master cylinder to clutch pedal retaining bolts (1).

Do not fully tighten at this stage.

3. Connect the push rod connector (3) to the clutch pedal pin (4).
4. Remove the clutch position switch. Refer to Clutch Pedal Position Switch Replacement.

Important: Measure from pedal pad bottom edge when at the top of travel to mod plate surface plane.

5. With an assistant raise clutch pedal to a height of 224 mm (a) to achieve the correct pedal height.

Notice: Refer to Fastener Notice in the Preface section.

6. Tighten the clutch master cylinder to clutch pedal retaining bolts (1).

Tighten
Tighten the bolts to 12  N·m (106 lb in).





Important: Pushing the pedal to the bottom of travel will assist with the clutch over centre spring (1) installation.

Important: Make sure that the clutch over centre spring (1) is installed in its original position.

7. Install the clutch over centre spring (1).
8. Install the clutch position switch. Refer to Clutch Pedal Position Switch Replacement.
9. Install the clutch pedal assembly. Refer to Clutch Pedal Replacement.
10. Reconnect the clutch patch harness to the cockpit harness.
11. Enable the SIR system. Refer to SIR Disabling and Enabling.
12. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.
13. Road test vehicle for correct clutch operation.