OEM 2005 Toyota Corolla Clutch Master Cylinder

2005 Toyota Corolla Parts Questions & Experts Answers

• Q: How to service and repair the Clutch Master Cylinder on 2005 Toyota Corolla?

  A: The service process for Clutch Master Cylinder starts with draining the clutch fluid followed by cleaning paint surfaces affected by brake fluid residue. The first step requires removal of the brake master cylinder sub-assembly together with the brake booster assembly followed by disconnection of the clutch reservoir tube by unclipping it. The Special Service Tool 09023-00101 allows users to cut off the clutch master cylinder flexible hose tube while catching the fluid into a storage container. The procedure requires two steps where the clutch pedal spring must be removed together with the clutch master cylinder push rod clevis hole pin which needs its clip and hole pin taken out. Unlock the clutch master cylinder assembly through the process of unscrewing its two attached nuts. The clutch master cylinder kit installation requires a pin punch tool and hammer for dislodging the spring pin then proceeding with the removal of the inlet union and grommet before unlocking the clevis lock nut. The push rod lock nut also needs removal. First extract the cylinder body boot before using snap ring pliers to unfasten the snap ring with piston rod forward pressure then remove the push rod from the cylinder body with caution regarding possible piston expulsion. First attach the cylinder to a workbench then detach the stop plate from the piston with spring while being mindful not to harm the cylinder body interior. The indicated parts must receive lithium soap base glycol grease treatment before the piston with spring goes into the cylinder and then the stop plate joins the push rod. After attaching the cylinder body with the push rod proceed with inserting the snap ring by pressing on the piston rod and finally place the boot on the cylinder body. Before installation, fasten the lock nut to the push rod and connect the clevis with the lock nut temporarily then install the inlet union along with a new grommet. Slide the drive tool inside the slotted spring pin until it stands out between 1.5 and 3.5 mm (0.059 to 0.138 inch). Attach the clutch master cylinder assembly while using two nuts that need a torque setting of 12 Nm (120 kgf-cm, 9 ft. lbs.). Hook the hole pin to the bush of the clevis then use the hole pin to join the clevis to the clutch pedal sub-assembly through the right side of the vehicle with a securing clip. Reinstall the clutch pedal spring before connecting the clutch master cylinder to the flexible hose tube through use of Special Service Tool: 09023-00101 then torque to 15 Nm (155 kgf-cm, 11 ft. lbs.). The clutch reservoir tube requires attachment to the clip where the white mark must face upward before reinstalling the brake booster assembly and brake master cylinder sub-assembly. The brake line and clutch pipe line should be bled using clutch fluid that is poured into the brake reservoir tank. Torque the clutch line to 8.4 Nm (85 kgf-cm, 73 inch lbs.). During the last step of the brake system service check the brake pedal height while inspecting and adjusting the clutch pedal sub-assembly and conducting leakage tests on both brake fluid and clutch fluid. Also verify that the reservoir contains sufficient fluid.