OEM 2003 Toyota RAV4 Clutch Master Cylinder

2003 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the Clutch Master Cylinder on 2003 Toyota RAV4?

  A: The servicing process of the Clutch Master Cylinder starts with wiper assembly removal followed by pliers usage to free the reservoir hose from its clip and later removing the hose from the inlet union while capturing fluid inside a container. Special Service Tool: 09023-00100 enables the disconnect of the clutch line where dripped fluid should go into a container. The service and repair of the Clutch Master Cylinder begins with using needle-nose pliers to remove its clip and pin followed by extracting the master cylinder through 2 nut removals and subsequent removal of its gasket together with the pedal stay bracket and master cylinder bracket. To begin disassembly tap the slotted spring pin out of the inlet union using a pin punch and hammer and then take off the grommet from both pieces. Use snap ring pliers to take out the snap ring after boot removal and while pushing the push rod. Then pull out the push rod with washer before removing the clevis and lock nut. To conclude the process remove the piston together with spring from inside the cylinder. The assembly process requires application of lithium soap base glycol grease to parts before putting the piston with spring inside the cylinder and adding the push rod with washer that requires pushing into the piston and securing with a snap ring. The first step is to attach the cylinder boot to its position before adding a short-term clevis and lock nut to the assembly and finally placing the new grommet along with inlet union onto the cylinder body while inserting the slotted spring pin by tapping it into place. The installation requires attaching the gasket together with pedal stay bracket and master cylinder bracket to the master cylinder followed by tightening 2 nuts with 12 Nm (120 kgf-cm, 9 ft. lbs.) torque. Implement the pin and pin clip to attach the clutch pedal to the push rod before completing the clutch line connection with Special Service Tool: 09023-00100 at a torque value of 15 Nm (155 kgf-cm, 11 ft. lbs.) or 14 Nm (143 kgf-cm, 10 ft. lbs.) when using the special tool using a 30 cm torque wrench (11.81 inch). Use pliers to attach the reservoir hose to the inlet union while directing the mark in the upward position and fasten it with the clip. The wiper assembly needs reinstallation while filling brake fluid into the reservoir followed by bleeding the clutch system and clutch pedal adjustment before leak checks.