OEM 2004 Toyota Solara Clutch Master Cylinder

2004 Toyota Solara Parts Questions & Experts Answers

• Q: How to overhaul the Clutch Master Cylinder on 2004 Toyota Solara?

  A: The overhaul process for the Clutch Master Cylinder starts with draining clutch fluid followed by removal of brake master cylinder sub-assy and brake booster assy. The clutch reservoir tube requires disconnecting by loosening the clip while catching the fluid in a container. The task involves breaking the connection between the clutch master cylinder and flexible hose tube with Special Service Tool: 09023-00100 to collect expelled fluid in a container. To remove the clutch master cylinder you must first delete the clevis hole pin by taking away both the clip and hole pin followed by uncoupling the two nuts. To install the clutch master cylinder kit users must employ a 5 mm pin punch along with a hammer to drive out the slotted spring pin which allows access to the inlet union and grommet then loosen the lock nut so they can remove the push rod clevis along with the lock nut before pulling off the boot from the cylinder body. Install snap ring pliers to remove the snap ring while applying force on the piston rod and proceed by carefully removing the push rod along with the stop plate from the cylinder before extracting the piston with spring while maintaining the interior cylinder body free from damage. First coat specified parts with lithium soap base glycol grease and insert the spring-loaded piston into the cylinder afterward press the stop plate onto the push rod before installing the push rod inside the cylinder body. Snap ring pliers enable you to install the snap ring under piston rod pressure before adding the boot and lock nut and temporary push rod clevis installation with the lock nut. The inlet union requires a fresh grommet followed by installation of the slotted spring pin while driving its protrusion to a range of 1.5 to 3.5 mm. You should install the clutch master cylinder assy with its two nuts against a torque specification of 12 Nm (120 kgf-cm, 9 ft. lbs.). Fit MP grease to the hole pin contact area and bush before attaching the clutch pedal assembly to the pin (use left vehicle entrance) and anchor with the clip. Connect the clutch master cylinder to the flexible hose tube with Special Service Tool: 09023-00100 while torqueing to 15 Nm (155 kgf-cm, 11 ft. lbs.) before connecting the clutch reservoir tube to the clutch master cylinder assy through the clip without tube twisting. Before reattaching the brake components the system requires bleeding through Special Service Tool: 09023-00100 beginning with the master cylinder and continuing with the brake line and clutch pipe line by filling the brake reservoir with clutch fluid. When complete torque the clutch system to 8.4 Nm (85 kgf-cm, 74 inch lbs.) while checking brake pedal height for adjustments followed by examining and adjusting the clutch pedal sub-assy before verifying brake and clutch fluid levels and leakages in the reservoir.