Hydraulic fluid is poisonous. It also dissolves paint well. Be careful not to allow liquid to come into contact with exposed areas of the body or eyes. Keep a rag handy to catch spilled liquid, and if it comes into contact with painted surfaces, immediately wash off the liquid with copious amounts of cold water.
Withdrawal
Before starting this procedure, contact your local auto parts stores regarding the purchase of a repair kit or a new slave cylinder. Depending on the availability and cost of the necessary parts, decide whether the cylinder is worth repairing or it is better to replace it. If you decide to repair the cylinder, follow the instructions included with the repair kit.
1. Remove the brake fluid reservoir cap (for left hand drive models) or hydraulic clutch fluid reservoir (for right hand drive models) and use a syringe to remove liquid from the reservoir. On left-hand drive models, the fluid level should be below the brake line connection to the master cylinder.
2. Jack up the vehicle and place it securely on axle stands.
3. Wipe the area around the hydraulic line union and disconnect the line from the slave cylinder. If possible, use a special wrench to avoid damaging the fitting. Keep a rag handy to collect spilled liquid. Seal the open end of the line to prevent fluid from escaping and contaminating the line. On models where access to the slave cylinder is difficult, it is better to unbolt the slave cylinder before disconnecting the fitting.
4. Give nuts of fastening of the executive cylinder and remove the cylinder from transmission.
Typical hydraulic clutch slave cylinder
1 - Hydraulic line
2 - Fixing nuts
3 - bleed valve
5. Inspect the plastic pusher tip and actuation lever for signs of wear. The tappet should only be worn at the end. Signs of wear on the lever should only be in the recess for the pusher. The presence of signs of wear on the sides of the pushrod or on the lever in other places than the recess indicates that the pushrod is unbalanced.
6. Examine the slave cylinder, checking for leaks. If the pusher seal is leaking, replace the slave cylinder. When installing a new cylinder, make sure it is the correct type. Conventional flywheel models use a 20.64mm slave cylinder; on models with a two-piece flywheel, a cylinder with a diameter of 22.2 mm is used.
Installation
1. Install in reverse order. Be sure to apply a light coat of molybdenum disulphide grease to the plastic tip of the pusher and make sure that the tip fits correctly into the recess in the engagement lever. Tighten nuts of fastening of the executive cylinder with the demanded effort.
2. Fill the reservoir with fresh fluid and bleed the hydraulic clutch system (see Section Bleeding the hydraulic clutch system).