Service Procedure

1. Disconnect the negative battery cable(s).





2. Disconnect the electrical connector for the clutch interlock switch (Figure 1).

3. Disconnect the clutch master cylinder push rod from the clutch pedal (Figure 1).

NOTE:
Do not attempt to save or reuse the clutch master cylinder push rod plastic clip. A new plastic clip is included in the repair package.

4. Using a 15 mm socket, remove and save the two clutch master cylinder retaining nuts.

5. Separate the clutch master cylinder from the dash panel. The clutch master cylinder push rod should be clear of the dash panel opening.

6. Lift the vehicle on an appropriate hoist.





7. Remove and save the two clutch slave cylinder retaining nuts (Figure 2).

8. Remove the slave cylinder from the transmission bellhousing.

9. Disconnect the hydraulic clutch line retaining clips from the vehicle's frame.

10. Remove and discard the old hydraulic clutch assembly from the vehicle.





11. Install the new plastic clutch pedal retaining clip to the new clutch master cylinder push rod (Figure 3).

12. Lower the vehicle from the hoist.

13. Install the new hydraulic clutch assembly into the vehicle. The hydraulic hose going to the slave cylinder must route between the steering shaft and the frame.

CAUTION:
Do not route the hydraulic hose over the steering shaft. Hydraulic hose failure may occur.

14. Lift the vehicle on the hoist.





15. Apply a small amount of wheel bearing grease to the plastic rod end of the slave cylinder (Figure 4).

CAUTION:
Do not remove the slave cylinder rod plastic retaining strap (Figure 4).

16. Install the slave cylinder onto the transmission bellhousing.

Install and tighten the slave cylinder nuts to 194 in. lbs. (23 N.m).





CAUTION:
Be sure to route the hydraulic clutch hose so that it is between the transmission case and the transmission vent hose (Figure 5).

17. Route the hydraulic clutch hose over the frame and fasten the retaining clips on the hose to the frame.

18. Install the plastic tie strap provided in the kit to the transmission case as shown in Figure 6.





19. Secure the hydraulic clutch hose with the tie strap installed onto the transmission case in Step 18 (Figure 6).

CAUTION:
The tie strap must secure around the hose connector body. Do not secure the tie strap to the braded hose.

20. Lower the vehicle from the hoist.

21. Install the clutch master cylinder retaining nuts. Tighten the nuts to 250 in. lbs. (28 N.m).

22. Snap the clutch master cylinder push rod to the clutch pedal.

23. Connect the electrical connector for the clutch interlock switch.

24. Depress and release the clutch pedal several times.

25. Connect the negative battery cable(s).

26. Verify proper clutch pedal operation.