Warning: Brake fluid is poisonous: if fluid comes into contact with skin, wash it off immediately and thoroughly: if fluid gets into the stomach or eyes, seek medical attention immediately. Some types of hydraulic fluid are flammable and may ignite when in contact with hot parts; when servicing a hydraulic system, it is best to treat any fluid as flammable and take appropriate precautions, just as you would with gasoline. Brake fluid has a discoloring effect, especially on plastics, so if the fluid spills, it should be washed off the surface with plenty of clean water. Finally, it should be noted that the fluid is hygroscopic (it absorbs moisture from the air). Old fluid may be contaminated and unsuitable for further use. When adding or replacing fluid, always use the recommended type of fluid, and make sure the fluid is fresh and stored in a well-sealed container.
Removal
1. Apply the parking brake, then jack up the front of the vehicle and support it on stands (see "Lifting the car and placing it on supports").
2. Working from the right side of the vehicle, place a container under the slave cylinder, then unscrew the hydraulic tube fitting from the rear of the cylinder. If desired, you can disconnect the flexible hose from the metal tube. Once the fluid has drained, plug the open ends of the tubes/hoses and the slave cylinder.
3. Loosen the two screws securing the slave cylinder to the gearbox bell housing, then remove the cylinder together with the pushrod (see fig. 4.3). Remove the adjusting washer.
Fig. 4.3. Removing the clutch slave cylinder from the gearbox bell housing
Disassembly
4. Using a screwdriver, carefully pry up the mounting ring and remove the pusher.
5. Tap the cylinder against a wooden block to push out the piston, then remove the piston and spring (see Fig. 4.5, a, b).
Fig. 4.5, a. Remove the piston of the working cylinder...
Fig. 4.5, b....behind him there is a spring
6. Wash all parts in clean hydraulic fluid, then position them for inspection (see fig. 4.6).
Fig. 4.6. Clutch slave cylinder parts
7. Check the inside surface of the cylinder and the piston. If scoring or wear steps are found, replace the cylinder assembly. If the cylinder is in good condition, a repair kit consisting of new rubber seals should be purchased. Never use old seals.
8. Remove the old seal from the piston and install the new one using only your fingers. To make installation easier, lubricate the gasket with clean hydraulic fluid. Make sure the sealing edge faces the piston spring.
9. Lubricate the inner surface of the cylinder and insert the spring, with the large turns towards the fitting on the cylinder.
10. Carefully insert the piston, aligning the protruding end with the center of the spring.
11. If necessary, install a new dust seal on the tappet, then insert the tappet into the cylinder. The end of the tappet with the dust boot should face the piston.
12. Press the new retaining ring into place and push it in to secure the push rod.
Installation
13. Begin installation by positioning the adjusting washer with the grooved side facing the bell housing.
14. Place the cylinder and push rod against the housing, making sure that the push rod aligns with the spherical recesses in the clutch release lever.
15. Install and tighten the mounting bolts.
16. Connect the tube and hose, then bleed the air from the hydraulic system as described in paragraph 6.