Toyota 04311-12080 Cylinder Kit, Clutch Master

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Before beginning this procedure, contact local parts stores and dealer service departments concerning the purchase of a rebuild kit or a new master cylinder, as the availability and cost of the necessary parts may dictate whether the cylinder is rebuilt or replaced. If rebuilding, inspect the bore. Disconnect the negative cable from the battery, then under the dashboard, disconnect the pushrod from the top of the clutch pedal by removing the clip and clevis pin. Disconnect the hydraulic line at the clutch master cylinder using a flare-nut wrench to prevent rounding off the fitting, and have rags handy for fluid loss. Remove the nut securing the master cylinder to the engine firewall and take out the master cylinder carefully to avoid spilling fluid. Drain all fluid from the master cylinder, and for 1989 and earlier models, remove the hold-down bolt inside the reservoir to pull off the reservoir; for 1990 and later models, drive out the spring pin and pry the reservoir off. Remove the dust cover on the pushrod and the snapring, then take out the retaining washer and pushrod. Tap the master cylinder on a block of wood to eject the piston assembly, separating the spring from the piston. Wash all reusable parts with brake cleaner or clean brake fluid, avoiding petroleum-based solvents, and carefully remove the seal from the piston. Inspect the bore for deep scratches or ridges; if not smooth, replace the master cylinder. If rebuilding, use the new parts from the rebuild kit and follow any specific instructions. Attach the seal to the piston with the seal lips facing away from the pushrod end, then assemble the shim, spring support, and spring on the piston. Lubricate the bore and seals with fresh brake fluid, guide the piston assembly into the bore without damaging the seals, and position the pushrod and retaining washer, compressing the spring to install a new snap-ring. Apply rubber grease to the inside of the dust cover and attach it to the master cylinder before installing the fluid reservoir. Position the master cylinder on the firewall and install the mounting nut(s) finger-tight. Connect the hydraulic line to the master cylinder, ensuring proper threading without cross-threading, then tighten the mounting nut(s) and hydraulic line fitting securely. Connect the pushrod to the clutch pedal, fill the clutch master cylinder reservoir with brake fluid conforming to DOT 3 specifications, and bleed the clutch system. Finally, check the clutch pedal height and freeplay, adjusting if necessary.

The availability and cost of the necessary parts.