DORMAN CM640001 Clutch Master Cylinder Installation Guide

Concentric Slave Cylinder Installation

NOTE: Replacing the concentric slave cylinder requires the transmission to be removed and reinstalled. Consult vehicle service manual for proper procedures.

IMPORTANT: If the Clutch Master Cylinder (M/C) on your vehicle is located at an angle on the firewall, it MUST be bench bled! Please see steps 7 through 12.

SLAVE CYLINDER CONCENTRIC STYLE

Quick Disconnect Tool

1. Carefully clean off the hydraulic tube coupling. Disconnect the hydraulic tube coupling at the transmission with the supplied hydraulic line Quick Disconnect (QD) tool by sliding the white plastic sleeve toward the slave cylinder.

2. Remove the transmission per your vehicle manufacturer’s Shop Manual.

3. Remove the concentric slave cylinder mounting bolts and remove from the transmission.

4. Clean the transmission input shaft and install the new concentric slave cylinder. Make sure the slave cylinder is installed flat against the transmission-mounting surface.

5. Install the slave cylinder attaching bolts and tighten per the vehicle manufacturer’s Shop Manual requirements. Check to make sure the slave cylinder is not cocked.
   Plastic (torque 3 to 5 Nm); Aluminum (15 to 20 Nm)

6. Reinstall the transmission per your vehicle manufacturer’s Shop Manual.

7. Remove the reservoir, Clutch M/C and clutch tube as one unit and support the reservoir in an appropriate fixture or tool such as a vise. Care must be taken not to damage the reservoir. Allow the Clutch M/C and tube to hang down from the reservoir. Fill the reservoir with an approved DOT 3 or 4 brake fluid. Hold the M/C so that the nose is up at a 45° angle, with the pushrod pointed down. With a blunt tool, depress the small valve in the middle of the quick connect coupling located at the end of the clutch tube. Keep the end of the tube and coupling pointed down.

8. Allow fluid to flow out of the coupling until a steady clear stream is observed. Remove the tool and allow the coupling to close. Check to be sure the reservoir is at least one half full. Check to be sure the O-Ring on the outside of the coupling is present, clean and undamaged. Replace if necessary and lubricate with DOT 3 brake fluid.

9. Keeping the reservoir end of the M/C pointed up, slowly depress the push rod. Observe the reservoir for air bubbles. Repeat until the push rod can only be pushed in 4mm or less. If resistance is still very low, repeat steps (9) and (10), until 4mm or less of free play remain.

10. Top off the reservoir with fluid. Replace the diaphragm and cap onto the reservoir.

11. Reinstall the reservoir, clutch M/C and clutch tube as one unit on the vehicle.

12. Reconnect the clutch tube by inserting the QD coupling into the coupling on the concentric slave cylinder. Make sure the line is secure in the coupling.

13. Pump the clutch pedal slowly 5-10 times, making sure that the pedal is allowed to return completely after each stroke.

14. Depress the clutch pedal and hold it down.

15. Slowly open the bleed screw on the concentric slave cylinder and allow any trapped air to escape. Close the bleed screw. Repeat process until there is a solid stream of fluid.

16. Torque the bleed screw and release the clutch pedal. Do not over tighten bleed screw.
    Bleed screw torque for Plastic housing (3 to 5 Nm).
    Bleed screw torque for Aluminum housing (15 to 20 Nm)

NOTE: Under normal usage, small amounts of air remaining will be purged from the system.

9999901 rev. 1

Documents / Resources

| DORMAN CM640001 Clutch Master Cylinder [pdf] Installation Guide
CM640001 Clutch Master Cylinder, CM640001, Clutch Master Cylinder, Master Cylinder, Cylinder
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