Hyundai Elantra HD: Clutch Master Cylinder. Repair procedures - Clutch System - Clutch System - Hyundai Elantra HD 2006–2010 Service ManualHyundai Elantra HD: Clutch Master Cylinder. Repair procedures

Removal

1.
Drain the brake fluid through the bleeding plug (A).
2.
Remove the flexible hose (A) connected to brake reserve tank from the master cylinder.
3.
Disconnect the clutch tube (B) from the master cylinder.
4.
Disconnect the two ignition lock switch connectors.
5.
Remove the clutch pedal mounting nuts(A-2ea) and the bracket mounting nut.
6.
Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).
7.
Remove the screws or nut mounting the master cylinder to the clutch pedal assembly.

Disassembly

1.
Remove the piston stop ring.
2.
Pull out the push rod and piston assembly.
3.
Remove the reserve tank band, reserve tank cap, and reserve tank.
1.
Use care not to damage the master cylinder body and piston assembly.
2.
Do not disassemble the piston assembly.

Installation

1.
Apply the specified grease to the clutch pedal and bushings.
Chassis grease : SAE J310a, NLGI No.1

2.
Install the screws or nut mounting the master cylinder to the clutch pedal assembly.
3.
Apply the specified grease to the snap pin(A) and washer.
Wheel bearing grease : SAE J310, NLGI No.2
4.
Connect the push rod to the clutch pedal by installing the snap pin (A) and washer (B).
5.
Install the clutch pedal mounting nuts (A-2ea).
Tightening torque :
25 ~ 35Nm (250 ~ 350kgf.m, 18.2 ~ 25.5Ib-ft)

6.
Adjust the clutch pedal within the standard value, then secure by tightening the lock nut.
Standard value
Free play (A)
6~13mm (0.24~0.51 in)
Height (B)
182.8mm (7.19 in)

7.
Connect the flexible hose of the brake reserve tank to the master cylinder.
8.
Connect the clutch tube(B) to the master cylinder.
9.
Refill the brake fluid.
10.
Bleed the air in the clutch system.(refer to Bleeding in Serive Adjustment Procedure)

Inspection

1.
Check the inside of the cylinder body for rust, pitting or scoring.
2.
Check the piston cup for wear or distortion.
3.
Check the piston for rust, pitting or scoring.
4.
Check to make sure the clutch line tube is not clogged or restricted in any way.
5.
Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.
Measure the inside diameter of the master cylinder at three places (bottom, middle, and top) in a perpendicular direction.
6.
If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly.
Limit : 0.15 mm (0.006 in)

Reassembly

1.
Apply the specified fluid to the inner surface of the master cylinder body (A) and to the entire periphery of the piston assembly (B).
Specified fluid : Brake fluid DOT 3 or DOT 4
2.
Install the piston assembly.
3.
Install the piston snap ring.
4.
Install the push rod assembly.

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