OEM 2003 Toyota Camry Clutch Master Cylinder

2003 Toyota Camry Parts Questions & Experts Answers

• Q: How to overhaul the Clutch Master Cylinder on 2003 Toyota Camry?

  A: The repair process of the Clutch Master Cylinder starts with draining the clutch fluid before proceeding with brake master cylinder sub-assembly and brake booster assembly removal. Start by opening the clutch reservoir tube clip to disconnect it while catching the fluid with a suitable container. The clevis whole pin can be removed by first unclipping it with its hole pin and then separating the clutch master cylinder push rod and its corresponding clevis pin. Follow up the removal of clutch master cylinder to flexible hose tube tube with the usage of Special Service Tool: 09023-00100 while placing fluid into a container. Then proceed to drive out the slotted spring pin of the clutch master cylinder kit by utilizing a 5 mm pin punch with a hammer then take away the inlet union and grommet followed by loosening the lock nut to detach the push rod clevis and finally take away the lock nut from the push rod. After removing the cylinder body boot proceed to slide in the piston rod while using snap ring pliers to remove the snap ring until you can extract the push rod out of the cylinder body while paying attention because the piston may exit suddenly. Take out the stop plate from the push rod and the piston with spring from the cylinder while being cautious of damaging the cylinder body interior. Install parts with lithium soap base glycol grease before placing the piston with spring inside the cylinder followed by stopping the sequence with stop plate installation and push rod fitting. Next install the snap ring followed by the boot while pushing the piston rod before you install the lock nut on the push rod. Afterward you can temporarily attach the push rod clevis using the lock nut. Insert the inlet union along with a new grommet into place before hammering and punching the slotted spring pin using a 5 mm pin punch. Last step is to fit the clutch master cylinder assembly through its two nuts then tighten them to 11.8 Nm (120 kgf-cm, 9 ft. lbs.) and finish by applying MP grease to the hole pin contact surface on its bush before joining the clevis to the clutch pedal assembly using the hole pin and finally adding a clip. Connect the clutch master cylinder to the flexible hose tube while using Special Service Tool: 09023-00100 and torque it to 15.2 Nm (155 kgf-cm, 11 ft. lbs.). Then use the clip to connect the clutch reservoir tube with the clutch master cylinder assembly without twisting it. The service technician should install the brake booster assembly and brake master cylinder sub-assembly before using Special Service Tool: 09023-00100 to bleed the master cylinder then proceed with bleeding the brake line and clutch pipe line followed by filling the brake reservoir tank with clutch fluid before bleeding the clutch system and torquing to 8.3 Nm (85 kgf-cm, 73 inch lbs.). The process concludes with examining brake pedal height and inspecting and setting the clutch pedal sub-assembly while inspecting brake and clutch fluid leakage and reservoir fluid level.