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

Removal

1.
Drain the brake fluid through the bleed plug(A).
2.
Disconnect the clutch tube(A).
3.
Remove the two clutch release cylinder mounting nuts(B-2ea).

Disassembly

1.
Remove the clutch hose, valve plate, spring, push rod, and boot.
2.
Remove any dirt from the piston bore opening of the release cylinder.
3.
Remove the piston from the release cylinder using compressed air.
•
Use rags to prevent the piston from popping out and causing injury.
•
Apply compressed air slowly. Keep the fluid from splashing in your eyes or on your skin.


Installation

1.
Coat the clutch clevis push rod specified grease.
Specified grease : CASMOLY L9508

2.
Install the release cylinder mounting nuts(B-2ea).
Tightening torque :
15 ~ 22Nm (150 ~220 kgf.cm, 11 ~ 16 lb-ft)

3.
Install the clutch tube(A).
4.
Refill the brake fluid.
5.
Bleed the air in the clutch system.
(refer to Bleeding in Service Adjustment Procedure)

Inspection

1.
Check the release cylinder bore for rust and damage.
2.
Measure the release cylinder bore at three locations (bottom, middle, and top) with a cylinder gauge and replace the release cylinder assembly if the bore-to-piston clearance exceeds the limit.
Limit : clearance to piston: 0.25mm (0.0098 in)

3.
Check the clutch release cylinder for fluid leakage.
4.
Check the clutch release cylinder boots for damage.

Reassembly

1.
Apply specified brake fluid to the release cylinder bore and the outer surface of the piston and piston cup, and push the piston cup assembly into the cylinder.
Specified fluid : Brake fluid DOT 3 or DOT 4
2.
Install the valve plate(A), Spring(B), push rod(C) and boot(D).

Clutch Release Cylinder. Components and Components Location
Components 1. Union bolt 2. Gasket 3. Tube joint 4. Clutch tube 5. Valve plate 6. Valve spring 7. Bleeder screw 8. Release cylinder 9. Retur ...