Toyota Corolla 2004 Repair Manual - CLUTCH MASTER CYLINDER ASSY

42–10

–CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)

OVERHAUL

1. DRAIN CLUTCH FLUID

2. REMOVE BRAKE MASTER CYLINDER SUB–ASSY (See page 32–13)

3. REMOVE BRAKE BOOSTER ASSY (See page 32–20)

4. DISCONNECT CLUTCH RESERVOIR TUBE

(a) Loosen the clip and disconnect the clutch reservoir tube

from the clutch master cylinder assy.
HINT:
Use a container to catch the fluid.

D07708

5. DISCONNECT CLUTCH MASTER CYLINDER TO

FLEXIBLE HOSE TUBE

(a) Using SST, disconnect the flexible hose tube.

SST 09023–00100

SST

HINT:
Use a container to catch the fluid.

4203P–02

D07707

6. REMOVE CLUTCH PEDAL SPRING

7. REMOVE CLUTCH MASTER CYLINDER PUSH ROD

CLEVIS W/HOLE PIN

(a) Remove the clip and hole pin.

D26327

8. REMOVE CLUTCH MASTER CYLINDER ASSY

(a) Remove the 2 nuts and clutch master cylinder assy.

2004 COROLLA (RM1037U)

1507Author: Date:

D07728

CL0533

42–11

–CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)

9. REMOVE CLUTCH MASTER CYLINDER KIT

(a) Using a pin punch and a hammer, drive out the slotted

spring pin.
(b) Remove the inlet union and grommet.
(c) Loosen the lock nut, and remove the clevis.
(d) Remove the lock nut from the push rod.
(e) Remove the boot from the cylinder body.

(f) While pushing the push rod, using snap ring pliers, re-

move the snap ring.
(g) Remove the push rod from the cylinder body.

NOTICE:
The piston may pop up out of the cylinder body. Therefore,
slowly remove the push rod from the cylinder body.

(h) Remove the stop plate from the push rod.
(i) Remove the piston with spring from the cylinder.

NOTICE:
Be careful not to damage the inside of the cylinder body.

10. INSTALL CLUTCH MASTER CYLINDER KIT

CL0528

CL0533

(a) Coat parts with lithium soap base glycol grease, as shown

in the illustration.
(b) Install the piston with spring into the cylinder.

NOTICE:
Be careful not to damage the inside of the cylinder body.

(c) Install the stop plate to the push rod.
(d) Install the push rod to the cylinder body.

(e) While pushing the push rod, using snap ring pliers, install

the snap ring.
(f) Install the boot to the cylinder body.
(g) Install the lock nut to the push rod.
(h) Temporarily install the clevis with the lock nut to the push

rod.
(i) Install the inlet union and a new grommet.

2004 COROLLA (RM1037U)

1508Author: Date: