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post #16 of (permalink) Old 26th May 2006
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Originally Posted by WebCode
You need

1: a small flat blade screw driver
2: a 24mm Spanner
3: a Stanley Knife
4: 0.5litres of brake/clutch fluid
5: an 8mm ring spanner

Firstly, look into the drivers footwell and remove the foam panel that covers the tops of the pedal assembly. Then look up at the clutch pedal, where you will see the clutch master cylinder pushrod attached to the clutch pedal pivot.. Use the flatblade screwdriver to snap off two of the three retaining clips that hold the pushrod to the pedal. Then detach the pushrod from the pedal pivot.

Take the engine cover off to gain better access to the cylinder. Looking onto the cylinder you must disconnect the metal pipe that plugs into the front of the cylinder. This is done by lifting the retaining clip halfway and pulling the pipe out..
Then follow the rubber flexible hose from the cylinder to the Brake resevoir. You must cut a slot in the pipe to remove it from the resevoir. Don't just pull it off as you will break the plastic takeoff pipe.. (in which case you will need an new resevoir..
Use the 24mm spanner and turn the master cylinder body clockwise and 1/8th of a turn to release it from the bulkhead. Remove it and throw away..

Refit the new master cylinder into the buklhead and then turn 1/8th turn anticlockwise to secure.. Plug the flexihose into the resevoir, Push the metal pipe into the front of the cylinder.
Get bak into the drivers foot well and push the pushrod back onto the pivot point.. IMPORTANT: Press the clutch pedal fully down. It will stay in that position.

Now you must bleed the system. The bleed point is located on the front of the gearbox and is difficult to access due to some coolant pipes. It is easier to get to from under the car..
Use the 8mm spanner to crack the bleed nipple of. Be VERY CAREFUL not to snap the Slave cylinder while doing this.. You may be able to get another spanner onto the slave housing to hold it..

You must use a pressure bleeder to correctly purge the clutch pipes of ALL old dirty fluid.
The system is bled in two stages. 1 with the pedal depressed fully, 2ndly with the pedal fully up..

Fill the bleeder with clean fluid, then bleed the system until the fluid runs clear. lock the nipple. Then pull the clutch pedal up. Bleed again until clear fluid and all air as been purged. Close nipple.
Release the pressure.. Get in the car and press the clutch pedal up and down 10-20 times.
You may have to repeat this procedure twice, as some air may not be purged completely first time round.. (if the pedal drops slightly when first depressed)

Job Done..
maximum respect m8ty will folow instuctions also, i wqonder how many peeps out there have had this problem and changed the clutch
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