Clutch Master Cylinder Repair/Replacement


NOTE: Some portions of the following instructions apply only to the AE92 GT-S. Use at your discretion.

    Signs & Symptoms:
  1. Your clutch master cylinder (MC) has steadily been losing fluid,
  2. Clutch pedal travel is different,
  3. Clutch seems more "grabby," and
  4. The area directly surrounding and below the clutch pedal is soaked with brake fluid.
    Diagnosis: The piston seals in the clutch MC have deteriorated causing brake fluid to leak out on either side of the firewall.
    Parts needed:
  1. Clutch MC assembly; PN 31410-12200, or
    MC rebuild kit; PN 04311-22022
  2. Clutch MC x Firewall gasket; PN 31415-10010 (Optional, but if the MC's leaking, both it and the gasket are prob'ly old)
  3. Clutch slave (release) cylinder, 2nd design; PN 31470-12093 (Optional, but contaminants could be wrecking the slave cylinder's seals)
  4. Brake fluid (duh!)
  5. Container to catch extra fluid during bleeding process
    Procedure...
  1. Remove air cleaner assembly and intake hose to T/B.
  2. Remove charcoal canister.
  3. Remove 3 bolts holding charcoal canister mounting bracket to frame rail.
  4. Move charcoal canister mounting towards the front as far as it will go without bending fuel lines.
  5. Drain all fluid out of clutch MC, slave cylinder, and line into suitable container.
  6. Remove MC reservoir parts (cap, float, bolt, reservoir, and washer).
  7. Disconnect fluid line from MC.
  8. Remove slave cylinder from bellhousing and set aside. (Optional)
  9. Remove driver's side underdash trim cover for access to clutch and brake pedal mechanisms.
  10. Remove safety circlip and clevis pin from brake pedal adjustment rod. DO NOT LOOSEN ROD ADJUSTMENT LOCK NUT!!!
  11. Remove safety circlip and clevis pin, clevis, and lock nut from clutch pedal adjustment rod.
  12. Remove 4 nuts holding brake booster to firewall.
  13. Remove 2 nuts holding clutch MC to firewall.
  14. Pull brake MC/booster assembly towards the front. DO NOT FORCE TOO MUCH!!!
  15. Pull clutch MC out. With the brake MC/booster pulled out, you should have just enough room.
  16. Repair or replace the clutch master cylinder. (If repairing, check MC bore for scratches/scoring)
  17. Install new clutch MC x firewall gasket.
  18. Install "new" clutch MC.
  19. Assemble parts using reverse procedures.
  20. Fill clutch reservoir with new, uncontaminated brake fluid.
  21. Bleed clutch cylinder system.
  22. Set proper clutch pedal freeplay.

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