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Incomplete clutch release and/or hydraulic fluid leaking into the cab from the clutch master cylinder may be caused by the reinforcement plate on the clutch master cylinder separating from the dash panel. The separation of the reinforcement plate reduces the clutch master cylinder pushrod travel. Reinforcement plate separation can also cause deflection of the clutch master cylinder that results in a misalignment of the pushrod to the clutch master cylinder. Misalignment causes the “O” ring in front of the secondary seal to leak hydraulic fluid. ACTION Inspect the truck and, if necessary, use the following service procedure to install a reinforcement kit. INSPECTION PROCEDURE 1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5″ (12.7 mm) from the floor. 2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear. 3. If the truck passes these tests, go to the Small Reinforcement Installation Procedure Section of this article. 4. If either of the above conditions are not met, check the hydraulic system for air. Refer to the Suggested Bleeding Procedure at the end of this article. 5. Test drive the truck and check for improved clutch release. 6. If there is no improvement, proceed as follows: a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever. b. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force

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NOTICE: To avoid paint damage, painted surfaces surrounding the master cylinder should be covered. 1. Using a line wrench, disconnect steel hydraulic line. The brake hydraulic system reservoir provides brake fluid for the clutch control system. To prevent loss of brake fluid during clutch master cylinder removal, the disconnected hydraulic fluid transfer hose must be plugged or directed into a suitable container. 2. Disconnect brake fluid transfer hose. 3. From engine compartment, remove lower mounting nut. 4. From passenger compartment, remove upper nut from clutch master cylinder mounting stud. 5. Remove clutch master cylinder and gasket. DISASSEMBLY 1. Press down on the piston and remove the stop wire with needle-nose pliers. 2. With stop wire removed, use compressed air to remove the piston and secondary cup assembly, primary cup and return spring. 3. Use brake fluid to clean inner parts.

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The hydraulic unit (pump, motor, supply reservoir) is located in the spare tire recess. If the switch for the roll-over bar convenience feature or the switch for the soft top is actuated, the pump (A7/5) runs as long as the switch is pressed, pumping hydraulic fluid at a pressure of approx. 180 + 20 bar . The pressure is limited to 180 bar by a pressure limitation valve.

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NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration. WARNING: Risk of Injury to skin or eyes due to hydraulic fluid spraying out under high pressure Risk of poisoning due to consuming hydraulic fluid NOTE: Before starting work on the hydraulic system, depressurize the system Wear protective clothing and safety gasses 1. Empty pressure oil system at rear axle 2. Connect tester to rear axle connecting piece (57) 3. Pour suitable oil into oil reservoir (2) NOTE: For testing, increase the quantity of oil to approx. 0.5 liters above the “max. ” marking (a) on the oil dipstick (2a) 4. Disconnect return (flow) line (T) at oil reservoir (2), connect oil drain hose (061) to the return (flow) line (T) and guide into oil reservoir (2) Pay attention to secure hose routing When the pressure relief valve in the valve unit opens, the oil pressure in the return (flow) line increases to approx. 2 bar 5. Connect Hand-Held Tester (HHT) (089) part No. 65 11 0001 99, or equivalent, with suitable test cable (094) to data link connector (X11/4) WARNING: Risk of accident due to vehicle starting off automatically when engine is running Risk of injury due to being trapped and burns when intervening while starting the engine or when the engine is running 6. Start engine and allow to idle WARNING: Secure vehicle to prevent it from starting off automatically Wear close-fitting, tight clothing Do not touch hot or rotating parts 7. Place HHT (089) in “lift” position NOTE: Only carry out the test briefly due to the high pressures. The delivery pressure of the pressure oil pump is limited by the bypass valve in the valve unit 8. Check opening pressure of bypass valve Delivery pressure at engine idle speed: 180-190 bar 9. Check delivery rate of pressure oil pump: Connect oil drain hose (061) to the return (flow) line (T) in a measuring vessel Ensure that there is sufficient oil in the oil reservoir. The pump must not draw in air under any circumstances Delivery rate at engine idle speed: 0.2 liters/min

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NOTE: If the drive belt is to be subsequently reused: Mark direction of travel and reinstall drive belt in same direction of travel. Remove fan clutch with impeller, refer to 11 52 020 REMOVING AND INSTALLING OR REPLACING FAN COUPLING (M62) . Layout of drive belt. Fig. 207: Layout Of Drive Belts Slacken screws (1) and relieve tension on belt drive. NOTE: Release screws (1 and 2) to remove complete belt tensioner. Remove drive belt. CAUTION: You must replace the drive belt if it is contaminated with hydraulic fluid.