How to Change a Clutch Master Cylinder in a Corolla

In a Toyota Corolla with manual transmission, the clutch has its own master cylinder. This cylinder works directly with the brake master cylinder and power brake booster, using the same brake fluid to operate the clutch. A leaking or damaged clutch master cylinder needs to be changed, and you will need to work with the other brake components in the engine to do this.

Things You'll Need

• Screwdriver
• Siphon tool
• Hose clamps
• Pliers
• Flare-nut wrench
• Flashlight
• Wrench
• Brake fluid
• Jack
• Jack stands
• Container

Instructions

Removal

1. Disconnect the car battery's negative cable.

2. Remove the knee bolster on the driver's side by removing its screws. DIsconnect the pushrod from the top of the clutch pedal by unclipping and removing the clevis pin.

3. Siphon out as much brake fluid from the brake master cylinder reservoir as you can using an unused syringe, turkey baster or other type of siphon tool. Clamp the fluid feed hose to the clutch cylinder and detach the hose from the reservoir.

4. Remove the brake master cylinder. Disconnect the brake lines from the cylinder with a flare nut wrench, cover or plug the openings with plastic bags or caps, remove the nuts connecting the cylinder to the power booster and remove it from its studs.

5. Remove the power brake booster. Remove the air filter housing, disconnect the vacuum hose from the booster, disconnect the brake lines and cruise control actuator, remove the nuts and washers holding the booster to the firewall and slide it off its studs.

6. Disconnect the hydraulic line at the clutch master cylinder using a flare nut wrench on the line's fitting. Have rags ready to catch fluid that drips out.

7. Remove the nuts that attach the cylinder to the firewall; reach underneath the dash to access the nuts. Try to avoid spilling fluid as you remove the master cylinder.

Installation

1. Position the replacement master cylinder on the firewall and install the mounting nuts, tightening them with just your fingers for now.

2. Connect the hydraulic line to the master cylinder. Move the cylinder's position slightly as needed to properly thread the line's fitting into the bore.

3. Tighten the hydraulic line and mounting nuts securely and connect the pushrod to the clutch pedal with its clevis pin.

4. Re-install the power brake booster and brake master cylinder, then connect the clutch fluid feed line to the brake fluid reservoir. You should bench-bleed the master cylinder before installing it.

5. Fill the reservoir with DOT 3 brake fluid and bleed the clutch system as described in section 3. Bleed the complete brake system as well.

Bleeding the Clutch

1. Raise the car and support it on jack stands. Locate the release cylinder on the left side of the clutch housing and the bleeder valve above the fitting for the hydraulic fluid line.

2. Take the dust cap off the bleeder valve and place a length of clear tubing on the valve. Submerge the hose's other end in two inches of fluid within a container.

3. Open the bleeder valve as a second person pushes the clutch pedal. Look for air bubbles in the hose and/or container, then close the valve and have the other person release the pedal when the fluid stops flowing.

4. Repeat step 3 until a solid stream of fluid comes out the hose, making sure the master cylinder's fluid level doesn't drop too far. Replace the dust cap, lower the car and top off the master cylinder reservoir.

Tips & Warnings

• You may need a flashlight to help remove parts like the power brake booster.

References

• "Chilton Toyota Corolla Repair Manual"; Jay Storer; Haynes North America; 2005

Resources

• How to Bench Bleed the Master Cylinder
• How to Bleed Brakes