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Removal & Installation 1) Drain master cylinder. Remove cotter pin, washer and clevis pin. Disconnect push rod from clutch pedal. Remove and plug hydraulic line at clutch master cylinder. 2) Remove retaining nuts, clutch master cylinder and gasket. To install, reverse removal procedure. Apply grease to clevis pin before installing. Fill reservoir and bleed clutch system. See BLEEDING CLUTCH HYDRAULIC SYSTEM. CLUTCH RELEASE CYLINDER Removal & Installation Remove and plug hydraulic line at release cylinder. Remove cylinder-to-transmission bolts. Remove clutch release cylinder. To install, reverse removal procedure. Apply grease to push rod-to- release fork contact area. Bleed clutch system. See BLEEDING CLUTCH HYDRAULIC SYSTEM. BLEEDING CLUTCH HYDRAULIC SYSTEM Attach hose to bleeder fitting located on clutch release cylinder, next to hydraulic line. Submerge other end of hose in container half full of clean brake fluid. Fill reservoir with brake fluid. Open bleeder fitting. Have assistant press clutch pedal to full release position. Close bleeder fitting. Release clutch pedal. Repeat until air bubbles no longer emerge from hose. Refill reservoir. OVERHAUL CLUTCH MASTER CYLINDER NOTE: DO NOT disassemble piston assembly. Disassembly Remove piston stop ring, damper and push rod assembly. See Fig. 6. Remove piston assembly. Note position of reservoir band for reassembly reference. Remove reservoir. Inspection & Reassembly Inspect components for corrosion, scoring or damage. Replace if necessary. Apply brake fluid to components during reassembly. On Montero, adjust clutch master cylinder push rod to 5.90" (150 mm). On Montero Sport, push rod adjustment is correct after adjusting clutch pedal free play and pedal height. See CLUTCH PEDAL FREE PLAY and CLUTCH PEDAL HEIGHT under ADJUSTMENTS. To reassemble, reverse disassembly procedure. Ensure piston moves freely in bore. Fig. 6: Exploded View Of Clutch Master Cylinder (Typical) Courtesy of Mitsubishi Motor Sales of America. |