8-6
Chapter 8 Clutch and driveline
8.3 Clutch release cylinder installation details
1 Bleeder screw 4 Hydraulic line
2 Banjo bolt 5 Body
3 Washers
11 Bleed the clutch hydraulic system following the procedure in Sec-
tion 9, then cf%ckthe pedal height and freeplay as described in Chapter 1.
8 Clutch release cylinder - removal, overhaul and installation
Refer to illustrations 8.3, 8.6a and 8.6b
Removal
1 The crutch release cylinder is located on the side of the transmission
bellhousing.
2 Raise the vehicle and support it securely on jackstands.
3 Disconnect the hydraulic line from the release cylinder. This is done
by removing the bolt from the banjo fitting on the cylinder body (see illus-
tration).
4 Remove the bolt(s) and pull off the release cylinder.
Overhaul
5 Pull off the dust boot and pushrod.
6 Mount the release cylinder body in a padded vise and use com-
pressed air to force the piston and spring out of the bore (see illustra-
tions).
7 Unscrew and remove the bleeder screw.
8 Examine the surfaces of the piston and cylinder bore for scoring or
’ bright wear areas. If any are found, discard the cylinder and purchase a
new one.
9 If the components are in good condition, wash them in clean brake
fluidRemove the piston cup and discard it, noting carefully which way the
cup lips face.
10 Obtain a repair kit which will contain all the necessary new items.
11 install the new piston cup using your fingers only to manipulate it into
position. Be sure the Tips face in the proper direction.
12 Dip the piston assembly in clean brake fluid before installing it and the
spring into the cylinder.
13 Reinstall the bleeder screw.
14 Complete the reassembly by installing the pushrod and the dust cov-
er. Be sure the dust cover is secure on the cylinder housing.
.-
lnsfallation
15 Installation is the reverse of the removal procedure. Use new sealing
washers at the banjofrtting. After the cylinder has beetinstalled, bleed the
clutch hydraulic system as described in Section 9.
8.6a With the cylinder padded to catch the piston, use
compressed air to force the piston out of the bore - make sure
your hands are not in the way of the piston!
7
2
‘1
8.6b An exploded view of the clutch release cylinder
I Valve p/ate
6 Conical spring .
2 Spring
7 Cap
3 Pushrod
8 Bleeder screw
4 Boots
9 Cylinder body
5 Piston and cup assembly
9 Clutch hydraulic system - bleeding
.-
Caution: Do notallow the brake fluid to contactanypaintedsutface of the AL
vehicle, as damage to the finish will result.
1
Bleeding will be required whenever the hydraulic system has been
dismantled and reassembled and air has entered the system.
2 First fill the fluid reservoir with clean brake fluid which has been stored _
in an airtight container, Never use fluid which has drained from the system
or has bled out previously, as it may contain grit and moisture.
3 Attach a rubber or plastic bleed tube to the bleeder screw on the re-
lease cylinder and immerse the open end of the tube in a glass jar contain-
ing an inch or two of fluid.
4 Open the bleeder screw about half a turn and have an assistant quick-
ly depress the clutch pedal completely. Tighten the screw and then have
the clutch pedal slowly released with the foot completely removed. Repeat
this sequence of operations until air bubbles are no longer ejected from the
open end of the tube beneath the fluid in the jar.
5 After two or three strokes of the pedal, make sure the fluid level in the-
reservoir has not fallen too low. Keep it full of fresh fluid, otherwise air WIII
be drawn into the system.
6 Xghten the bleederscrew on a pedal down stroke (do notovertighten
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