Clutch release cylinder and accumulator — removal and installation
Clutch release cylinder 2009 and earlier models
Removal
1. Disconnect the negative cable from the battery (see Engine electrical systems).
2. Remove the air filter housing (see Fuel and exhaust systems).
3. To disconnect the hydraulic line from the release cylinder, unscrew the threaded fitting. If available, use a flare-nut wrench on the fitting, which will prevent the fitting from being rounded off. Have a small can and rags handy, as some fluid will be spilled as the line is removed.
4. Remove the mounting bolts and separate the release cylinder from the accumulator bracket.
Installation
5. Connect the hydraulic line to the release cylinder. Install the release cylinder on the bracket, making sure the pushrod is seated in the release fork pocket. Tighten the nuts to the torque listed in this Chapter’s Specifications.
6. Tighten the hydraulic line threaded fitting securely.
7. Fill the clutch master cylinder with brake fluid (conforming to DOT 3 specifications).
8. Bleed the system (see Clutch hydraulic system — bleeding).
9. Install the air filter housing and reconnect the battery.
2010 and later models
Removal
10. Remove the engine/transaxle assembly, then separate the transaxle from the engine (see Manual transaxle).
11. Disconnect the hydraulic line from the release cylinder. If available, use a flare-nut wrench on the fitting, which will prevent the fitting from being rounded off.
12. Remove the release cylinder mounting bolts and slide the release cylinder off of the transaxle input shaft bearing retainer.
Installation
13. Clean the inside of the clutch housing area with brake system cleaner.
14. Apply a small amount of high temperature grease to the input shaft retainer and slide the release bearing cylinder on to the input shaft retainer.
Note: Clean off any extra grease, making sure none gets on the input shaft splines.
15. Connect the hydraulic line to the release cylinder, but don’t tighten the fitting yet. Install the release cylinder and new mounting bolts, then tighten the bolts to the torque listed in this Chapter’s Specifications.
16. Tighten the hydraulic line threaded fitting securely.
17. Install the transaxle to the engine, then reinstall the engine/transaxle assembly.
18. Fill the clutch master cylinder with brake fluid (conforming to DOT 3 specifications).
19. Bleed the system (see Clutch hydraulic system — bleeding).
Accumulator 2009 and earlier models
Removal
20. Disconnect the negative cable from the battery (see Engine electrical systems).
21. Remove the air filter housing (see Fuel and exhaust systems) and the air inlet duct.
22. Remove the accumulator bracket mounting fasteners and bracket.
23. Remove the release cylinder heat insulator mounting fasteners and heat insulator.
24. Unscrew the hydraulic line fittings from the accumulator and release cylinder, then remove the mounting bolts from the accumulator. If available, use a flare-nut wrench on the fitting, which will prevent the fitting from being rounded off. Have a small can and rags handy, as some fluid will be spilled as the line is removed.
Installation
25. Connect the hydraulic lines to the accumulator, but don’t tighten them completely yet. Install the accumulator mounting bolts and tighten them to the torque listed in this Chapter’s Specifications. Tighten the hydraulic line fittings securely.
26. The remainder of installation is the reverse of removal.
27. Bleed the hydraulic system (see Clutch hydraulic system — bleeding).
2010 and later models
Removal
28. Disconnect the negative cable from the battery (see Engine electrical systems).
29. Loosen the left-front wheel lug nuts, raise the front of the vehicle and support it securely on jack stands, then remove the wheel. Remove the inner fender splash shield (see Body).
30. Remove the air filter housing (see Fuel and exhaust systems) and the air inlet duct.
31. Unscrew the hydraulic line fittings from the accumulator and release cylinder. If available, use a flare-nut wrench on the fitting, which will prevent the fitting from being rounded off. Have a small can and rags handy, as some fluid will be spilled as the line is removed.
32. Remove the clutch orifice assembly mounting fasteners and the U-clip from the bracket with a pair of pliers and separate the clutch hose.
33. Remove the accumulator mounting bolts and accumulator assembly.
Installation
34. Install the accumulator mounting bolts and tighten them to the torque listed in this Chapter’s Specifications. Connect the hydraulic lines to the accumulator and tighten the hydraulic line fittings securely.
35. The remainder of installation is the reverse of removal.
36. Bleed the hydraulic system (see Clutch hydraulic system — bleeding).