Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. Clean the area around the quick disconnect coupling. 3. Lower the vehicle. 4. Remove the two screws and the lower steering column finish panel. 5. Remove the five bolts and the lower reinforcement panel. 6. Disconnect the clutch pedal position (CPP) switch electrical connector. 7. Disconnect the clutch master cylinder rod from the clutch pedal arm. 8. Remove the CPP switch. Lift the upper cover from the lock tabs and pull the upper cover up. Rotate and remove the CPP switch from the clutch master cylinder rod. 9. Remove the reservoir. 10. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 11. Unclip the hydraulic line-to-frame retainer. 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. Unlock and remove the clutch master cylinder assembly. Twist the clutch master cylinder counterclockwise 45 degrees to unlock it from the support bracket. 13. Remove the reservoir, the hydraulic line and the clutch master cylinder as an assembly. 14. 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. To install, reverse the removal procedure. Install a new push rod retainer. Depress and release the clutch pedal 15 strokes.

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1. Raise and support the vehicle. Using the Hydraulic Line Connector Remover (308-182, T88T-70522-A), disconnect the hydraulic line from the clutch slave cylinder. See Fig. 9 . 2. Lower the vehicle. Remove the 2 screws and the lower steering column finish panel. See Fig. 10 . Remove the 5 bolts and the lower reinforcement panel. See Fig. 11 . 3. Remove the clutch master cylinder reservoir. See Fig. 16 . Remove the 3 push pins, 4 bolts, 4 screws and the inner fender splash shield. 4. Unclip the hydraulic line-to-frame retainer. Twist the clutch master cylinder clockwise 45 degrees to unlock it from the support bracket. See Fig. 17 . Remove the clutch master cylinder reservoir, the slave cylinder hydraulic line and the clutch master cylinder as an assembly. 5. Install a NEW clutch master cylinder push rod bushing. To install, reverse the removal procedure. Rotate the clutch master cylinder 45 degrees counterclockwise. Bleed the clutch hydraulic system. See BLEEDING .

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Removal 1. Note the routing of the clutch slave cylinder to clutch master cylinder tube (7A512) line from clutch master cylinder (7A543) to the clutch slave cylinder. 2. Remove retainer pin from clutch master cylinder holding clutch slave cylinder to clutch master cylinder tube in place. 3. Raise the vehicle and install suitable safety stands. 4. Disconnect clutch slave cylinder to clutch master cylinder tube from external clutch slave cylinder. On vehicles equipped with concentric clutch slave cylinders, remove tube using Clutch Coupling Tool T88T-70522-A. Installation 1. Follow the removal procedures in reverse order. 2. Bleed system. Refer to appropriate clutch hydraulic system bleeding procedure in the Adjustments portion of this section. Hydraulic Clutch Control System, 4.9L, 5.0L and 5.8L Gasoline Engines with Mazda R2 and S5-47 ZF Light-Duty and 7.3L and 7.5L S5-47 ZF Heavy-Duty Transmissions

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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).

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Hydraulic Clutch Control System IMPORTANT: The clutch hydraulic system is to be serviced as a COMPLETE UNIT!!!. It is a sealed unit and has been filled with fluid and bled of air at the factory. Individual components of the system are not available for service, except the slave cylinder actuator pushrod plastic retainer strap. Do not attempt to bleed the clutch hydraulic system. The bleed screw located on the clutch hydraulic slave cylinder is used for the factory fluid fill only. WARNING: Do not attempt to bleed the clutch hydraulic unit. Any observed fittings are there for factory use only. The unit comes as a complete pre-bled unit. REMOVAL 1. 2. 3. 4. 5. 6. 7. Block clutch pedal up to prevent pedal from being depressed with slave cylinder removed from transaxle. Remove air induction system. Disconnect negative battery cable from battery. Disconnect positive battery cable from battery Remove hold-down retaining nut and screw, and lift off battery hold-down retainer. Lift the battery of vehicle, and place in a safe location. Remove battery tray bolts and tray. IMPORTANT: One bolt is located in the fender well. NOTICE: Removal of the hydraulic damper with a power tool prior to removal of the actuator could result in breaking off the hydraulic line. IMPORTANT: Prior to removing the slave cylinder from the clutch housing, make sure that the clutch hydraulic system has sufficient fluid. Refer to the “Clutch Hydraulic Fluid Check” procedures in this manual. (This is not necessary if the clutch hydraulic system is being removed to be replaced.) 8. Rotate actuator 1/4 turn counterclockwise while pushing toward housing in order to disengage the bayonet connector and remove from clutch housing. 9. Remove two hydraulic damper to clutch housing nuts and slide damper and bracket assembly off studs.