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Master Cylinder-RHD: Installation

NOTE: These models are equipped with a one-piece master/slave cylinder assembly. If the master cylinder requires replacement, the master AND slave cylinder must be replaced with a two-piece "quick-connect" system. If the slave cylinder requires replacement, the slave cylinder is serviced separately.
NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required.
  1. Install the master cylinder into position on the dash panel. See Fig 1.
  2. Seat the master cylinder in the pedal bracket assembly.
    Fig 1: Clutch Master Cylinder-RHD
    GC0019827Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER
    2 - RESERVOIR
    3 - RETAINER
    4 - RETAINER
  3. Rotate the master cylinder approximately 45° in the clockwise direction.
  4. Route the hydraulic tube as noted upon removal.
  5. Raise vehicle on hoist.
  6. If master cylinder is being replaced, install service replacement slave cylinder. If master cylinder is being re-used, install slave cylinder as shown in Figure.
  7. If master cylinder is being replaced, connect the master cylinder hydraulic line to the service replacement slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line.
  8. Lower vehicle.
  9. Install the master cylinder remote reservoir onto the dash panel.
  10. Install the reservoir retaining screws. Tighten the screws to 3 N.m (24 in. lbs.).
  11. Install the clutch interlock/upstop switch and cover plate. See Fig 2
    Fig 2: Clutch Interlock/Upstop Switch
    GC0019780Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERLOCK/UPSTOP SWITCH
    2 - MASTER CYLINDER
    3 - CONNECTOR
    CAUTION: Inspect the clutch master cylinder push rod plastic retainer for damage. If it is damaged (broken/cracked), it MUST be replaced.
  12. Install the push rod onto the pedal pin.
  13. Depress and release the clutch pedal a minimum of ten (10) times to allow any residual air in the system to be vented to the reservoir. If residual air becomes trapped in the system, bleed the clutch hydraulic system. (Refer to CLUTCH - STANDARD PROCEDURE) 
  14. Connect the negative battery cable.
  15. Top off clutch master cylinder reservoir with DOT 3 brake fluid.
  16. Verify proper clutch operation.
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