replacement cylinder is not available, or the cost of
replacement is excessive. If a new or remanufactured mas-
ter or slave cylinder cannot be located, the old cylinder
can be rebuilt with the proper seal kit.
Rebuilding a master or slave cylinder is relatively
simple. It is similar to rebuilding brake system cylinders.
Refer to the exploded views of typical master and slave
cylinders in Figure 7-14. Following is a typical rebuilding
procedure:
1. Remove any rubber boot that covers the free end of
the piston.
2. Remove the snap ring that holds the piston in the
cylinder bore. The piston should slide out of the cylin-
der. In some cases, the piston will pop out of the
cylinder because of a return spring behind it. If the pis-
ton is stuck, it can be removed by tapping the cylinder
on a wooden block or by carefully applying air pres-
sure to the inlet connection.
Warning: Air pressure can cause the piston
to fly out with great force. Point the open
end of the cylinder away from yourself and
others and toward rags or some other soft surface
before applying pressure.
Chapter 7 Clutch Problems, Troubleshooting, and Service 135
Clevis pin
Bushing
Screw
Cable
mounting
bracket
Clutch
cable lever
Dash
panel
Throw out
lever
Clutch housing
Link
Figure 7-12. This is a typical cable linkage. A replacement cable must be routed so that it does not seize or bind. The original routing
is normally the best. (DaimlerChrysler)
Leaking
slave
cylinder
Clutch fluid
reservoir empty
Clutch pedal
pushrod
bent or off
Leaking
feed line
Internal leak
in clutch
master cylinder
Smashed or leaking
pressure line
Figure 7-13. Common sources of hydraulic linkage problems
are shown. The pushrod for actuating the master cylinder pis-
ton may be bent or disconnected, but most problems are
caused by low fluid level or by plugged hydraulic lines. Leaks
are usually responsible for low fluid levels. Kinks can cause
plugging of hydraulic lines. (Ford)