PITA CLUTCH MAST. CYL. REPLACEMENT

Exedy/Daiken Clutch, Clutch Master Cylinder

This little project is quite the pain. The space issue is quite the mess. Alot of bolts broke (havent been touched in 24 years).  I recommend spraying all bolts in penetrating oil before attempting.

1) Remove rod/pin and cotter pin connecting cylinder rod to clutch pedal

2)remove 3 nuts from cruise control pump (one up top on strut tower, two in wheel well.. all 3 broke for me)..

3)remove black relay box on strut tower (i didnt.. in retrospect that would have made it easier

4) if cylinder isnt already dry, drain fluid by opening valve on slave, and pump clutch pedal

5)loosen and remove hydraulic line from master cylinder. remove reservoir cap.

6) loosen and remove two 12mm spinning nuts attaching cylinder to fire wall (this is the biggest headache i had as my open end wrench rounded the corners.. there isnt enough space for deep sockets and the studs go thru the nuts over 1cm.. offset wrench or pass thru socket is require. i used pass thru socket)

7) shimmy it out. try getting bottom side off stud first.  and rest should be easy.

8) install new master cylinder in reverse order (do not fully tighten fire wall nuts until cylinder rod has been adjusted and pin inserted. this must be done with clutch pedal depressed and in normal position)

9) tighten everything and pour DOT3 fluid in until it pours out of the slave. tighten slave as soon as u see fluid. 

10) reinstall relay box and cruise control pump... and have a nice cold water.