OEM 2005 Toyota Solara Clutch Master Cylinder

2005 Toyota Solara Parts Questions & Experts Answers

• Q: How to service and repair the clutch master cylinder assembly on 2005 Toyota Solara?

  A: Service and repair of the clutch master cylinder assembly begins with draining fluid after which other components such as brake master cylinder sub-assembly and brake booster assembly can be removed. Start by letting go the clutch reservoir tube clip and placing a container under the tube to collect the fluid. Special Service Tool: 09023-00101 enables you to disconnect the clutch master cylinder to flexible hose tube where you must utilize a container to hold the fluid. Begin removal of the clutch master cylinder push rod clevis hole pin by unscrewing its two nuts then take out the clip and hole pin. A pin punch (5 mm) with hammer can drive out the slotted spring pin so you can remove the inlet union with grommet and let the lock nut provide access to the push rod clevis before unlocking the push rod nut. Take the cylinder body boot off next apply snap ring pliers to remove the snap ring by pushing on the piston rod, and extract the push rod from the cylinder body being careful about the potential piston ejecting out. Yank the stop plate from the push rod followed by extracting the piston with spring from the cylinder body working to prevent any damage to its inner chamber. Begin the installation process by applying lithium soap base glycol grease onto specified components then position the piston and spring inside the cylinder before you put the stop plate on the push rod before finishing with push rod attachment to the cylinder body. Begin by using snap ring pliers to apply the snap ring when pushing on the piston rod. After that install the boot to the cylinder body before locking the push rod with its respective nut. First clamp down the push rod clevis to the push rod through lock nut installation before adding the inlet union and fresh grommet with a 5 mm slotted spring pin drive using a pin punch. The clutch master cylinder assembly must be installed with a torque of 12 Nm (120 kgf-cm, 9 ft. lbs.) when securing the 2 nuts. Install the clutch pedal assembly clevis by inserting the hole pin from the left side of the vehicle then secure it with a clip after applying MP grease to the hole pin contact surfaces and bushing. Mount the clutch master cylinder to its flexible hose tube through tool 09023-00101 while tightening to 15 Nm (155 kgf-cm, 11 ft. lbs.) and finally apply the clutch reservoir tube to the clutch master cylinder assembly with a clip that will not create twisting motion. The technician should reinstall the brake booster assembly and brake master cylinder sub-assembly before using Special Service Tool: 09023-00101 to bleed the master cylinder followed by bleeding the brake line and clutch pipe line while filling the brake reservoir tank with clutch fluid. A torque of 8.4 Nm (85 kgf-cm, 74 inch lbs.) must be reached for the clutch system. Additionally check and adjust the brake pedal height and inspect and adjust the clutch pedal sub-assembly before conducting checks for both brake and clutch fluid leakage and reservoir fluid level.