OEM 2003 Toyota Corolla Clutch Master Cylinder

2003 Toyota Corolla Parts Questions & Experts Answers

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

  A: You must drain clutch fluid before taking out brake master cylinder sub-assembly together with brake booster assembly to do an overhaul of Clutch Master Cylinder. Seize the clutch reservoir tube while loosening its clip then preserve the fluid with a suitable container. Next the operator must disconnect the clutch master cylinder to flexible hose tube using Special Service Tool 0902-00100 while capturing the fluid into a designated container. Detach the clutch pedal spring and uninstall the clutch master cylinder push rod clevis with hole pin by extracting its clip and pin. Execute the removal of the clutch master cylinder assembly by unfastening the two nuts. Apply hammer and pin punch to remove the slotted spring pin then detach the inlet union and grommet and loosen the clevis lock nut followed by unfastening the push rod lock nut before removing the cylinder body boot. Apply snap ring pliers to remove the snap ring from the cylinder body as you push the push rod. Extract the push rod from the cylinder body by being diligent since the piston might eject itself. Install the stop plate onto the push rod then place the piston with spring inside the cylinder body yet avoid damaging any inside segments. The procedure to install the clutch master cylinder begins with applying lithium soap base glycol grease to parts before placing the piston with spring into the cylinder and adding the stop plate to the push rod and finally securing the push rod to the cylinder body. Apply snap ring pliers to install the snap ring before putting on the boot next to the cylinder body then finally secure the lock nut to the push rod. Install the clevis together with its lock nut on the push rod until you complete installation of the inlet union along with its new grommet while driving the slotted spring pin into place. The clutch master cylinder assembly needs installation with two nuts which should be torqued to 11.8 Nm (120 kgf-cm, 9 ft. lbs.). Use MP grease on the hole pin contact surface and clevis bush before fitting the clutch pedal sub-assembly to the hole pin from the right side position through the clear installation of the pin. Finally attach the clip to the hole pin. Hook the clutch master cylinder to the flexible hose tube through Special Service Tool: 09023-00100 while torquing it to 15.2 Nm (155 kgf-cm, 11 ft. lbs.). The apparatus of the clutch master cylinder assembly should receive the clutch reservoir tube connection using a clip that presents the white marking toward the top position. Installation of the brake booster assembly and brake master cylinder sub-assembly should be followed by bleeding both brake line and clutch pipe line with clutch fluid in the brake reservoir tank. The service technician should torque the clutch pipe line to 8.4 Nm (85 kgf-cm, 73 inch lbs.) before measuring the brake pedal height and inspecting the clutch pedal sub-assembly and brake and clutch fluid levels and leakages in the reservoir.