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2000 Ford F-Super Duty 250-550 Clutch Master Cylinder and Reservoir REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 08-03-2011

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Removal CAUTION: Remove the entire clutch hydraulic system from the vehicle as an assembly when installing a new clutch master cylinder assembly (7C522). 1. Disconnect the clutch hydraulic tube from the dash clip. 2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Unlock and remove the slave cylinder (7A564) from the transmission. Compress and twist the slave cylinder to unlock it from the transmission. 4. Disconnect the clutch hydraulic tube from the floor pan clip. Position the slave cylinder and hydraulic tube forward below the left engine bank. This will make it easier to unlock the clutch master cylinder from the clutch pedal and support bracket (7B633) by reducing tension on the hydraulic tube. 5. Lower the vehicle. 6. WARNING: The clutch pedal is under spring tension. Unlock the push rod bushing retaining clips and separate the clutch master cylinder push rod from the clutch pedal. 7. Remove and discard the push rod bushing (7526). 8. Remove the switch cover, and remove the clutch pedal position switch (7C534) from the clutch master cylinder push rod. 9. Separate the power distribution box from the bracket to gain access to the clutch master cylinder. 10. Unlock and remove the clutch master cylinder from the clutch pedal and support bracket. Compress and twist the clutch master cylinder clockwise 45 degrees to unlock it from the clutch pedal and support bracket. 11. Remove the clutch hydraulic reservoir from the wiring tray and separate the clutch hydraulic tube from the brake master cylinder assembly. Position the clutch hydraulic reservoir aside. 12. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Remove the clutch hydraulic system from the vehicle. 13. Clean the clutch hydraulic system components to prevent contaminants from entering the hydraulic system. 14. CAUTION: Place a suitable container under the clutch master cylinder. Disconnect the hydraulic tube from the clutch master cylinder. 1. Using a 3/32-inch punch and a hammer, drive out the roll pin, and discard it. 2. Disconnect the hydraulic tube from the clutch master cylinder.

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1999 Kia Sportage Clutch Slave Cylinder: Service and Repair

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Filed Under (KIA) by admin on 15-09-2010

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RELEASE CYLINDER Removal To prevent loss of brake fluid during clutch slave cylinder removal, the disconnected steel hydraulic line must be plugged or directed into a suitable container. 1. Disconnect flexible hose from steel hydraulic line. NOTICE: Twisting may damage the flex hose. 2. Remove hydraulic line retainer clip. 3. Remove two bolts. Disassembly 1. Remove flexible hose, boot, and push rod. 2. Remove piston and cap assembly and return spring. 3. Remove bleeder cap, bleeder screw, and steel ball. 4. Use brake fluid to clean inner parts. Inspection After cleaning, inspect the following parts: 1. Release cylinder bore and piston for wear. 2. Weak return spring. Assembly 1. Coat the piston and cups with clean brake fluid. 2. Insert steel ball in cylinder bleeder hole and secure with bleeder screw. 3. Push bleeder cap over bleeder screw end. 4. Insert return spring and piston and cup assembly into cylinder bore. 5. With boot installed on push rod, insert rod into cylinder bore and snap boot in place. 6. Connect flexible hose to the cylinder body. Tighten flexible hose nut to 16 ft. lbs. (22 Nm). Installation 1. With cylinder push rod in clutch arm detent, attach cylinder to the transmission case with two bolts. Tighten bolts to 17 ft. lbs. (23 Nm).

FORD LIGHT TRUCK: 1993 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER UNRESPONSIVE CLUTCH: AIR ENTRAPPED IN HYDRAULIC SYS

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Filed Under (Ford) by admin on 07-01-2011

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ISSUE A “soft” unresponsive clutch pedal may be felt or the driver may be unable to release the clutch. This is caused by air entrapped in the clutch hydraulic system. ACTION Use the information in this TSB article in addition to the appropriate bleeding procedure. This article includes detail as well as extra service tips for easier hydraulic clutch bleeding. The clutch hydraulic system for the 1993 model year is new and more difficult to bleed than the previous hydraulic system. Therefore, a different bleeding procedure is required for these vehicles. RANGER, EXPLORER, AEROSTAR The most difficult systems to bleed are on the Ranger, Explorer, Aerostars. NOTE: When installing dry clutch cylinder or tube service parts, do the bench bleed procedure first. BENCH BLEED The compact vehicles are more difficult to bleed because the downward angle of the master cylinder makes it difficult for air to escape up into the reservoir. Therefore, if the master cylinder is removed from the vehicle and bled while held in a vertical orientation (a bench bleed) air can escape much more efficiently. Refer to Fig. 1 . BENCH BLEEDING PROCEDURE (CONCENTRIC SLAVE CYLINDER) 1. Remove master cylinder, line and reservoir from vehicle and assemble with replacement parts required based on initial concern. 2. Hold the master cylinder vertically with the reservoir feed hose in the highest position on the body. See Fig. 1 . 3. Fill the reservoir and extend above the master cylinder and assure the quick connect on the clutch line is below the master cylinder. (Lightly clamp reservoir in a vise). 4. Using a small screwdriver, depress the internal mechanism of the male quick connect coupling to open the valve. See Fig. 1 . 5. Stroke and hold master cylinder pushrod. 6. Close quick connect valve. 7. Release master cylinder pushrod. 8. Fill reservoir. 9. Repeat Steps 4 through 8 four more times. 10. With the master cylinder still being held with the outlet tube and reservoir feed tube ends high, quick connect closed and the reservoir full, proceed as follows: a. Push the pushrod into the body several times quickly to expel any remaining air. b. If it is a remote reservoir, pinch the supply hose with your fingers two or three times to help move air into reservoir. 11. When the movement of the pushrod is .130″ (4mm) or less when stroked in Step 10, reinstall the master cylinder into the vehicle and couple it to the slave cylinder.

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2004 Suzuki Forenza Concentric Slave Cylinder Removal and Installation Removal

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Filed Under (Suzuki) by admin on 30-10-2010

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1. Remove the transaxle from the vehicle. 2. Remove the concentric slave cylinder retaining bolts. 3. Disconnect the concentric slave cylinder pipe from the concentric slave cylinder. 4. Remove the bushing from the concentric slave cylinder pipe in the transaxle housing. 5. Remove the concentric slave cylinder pipe. 6. Remove the O-ring and the concentric slave cylinder. Installation 1. Install the concentric slave cylinder and the pipe. 2. After installing the pipe screw provisionally, tighten the concentric slave cylinder retaining bolts. Tighten the concentric slave cylinder retaining bolts to 7 Nm (62 inch lbs.) . 3. Tighten the pipe screw. Tighten the pipe screw to 15 Nm (11 ft. lbs.) . 4. Install the bushing onto the transaxle housing. 5. Connect the pipe with bushing. 6. Install the transaxle into the vehicle.

1997 Toyota Camry LE Sedan 4-Door Cylinder Head Installation

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Filed Under (Toyota) by admin on 05-08-2010

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1. Install cylinder head. A. Place cylinder head on cylinder block. (a) Place a new cylinder head gasket on the cylinder block. CAUTION: Be careful of the installation direction. (b) Place the cylinder head on the cylinder head gasket. B. Install cylinder head bolts. NOTE: The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)). If any cylinder head bolt is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Cylinder Head Installation Install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes, in the sequence shown. Torque: 49 Nm (36 ft. lbs.) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. (c) Mark the front of the cylinder head bolt head with paint. (d) Retighten the cylinder head bolts 90° in the numerical order shown. (e) Check that the painted mark is now at a 90° angle to the front. Install the 2 bolts holding the water bypass pipe to the cylinder head. Torque to 19 Nm (14 ft. lbs.) (g) Connect the camshaft position sensor connector. 2. Install spark plug tubes. (a) Clean the cylinder head tube holes of any residual adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline. (b) Screw the threads of the spark plug tube coated with adhesive into the cylinder head.

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