15 CLUTCH 10. SLAVE CYLINDER 10A. DISMANTLING OF SLAVE CYLINDER (Fig.8) ● Remove circlip (4) and washer (2). ● Remove dust cover (3). ● Remove plunger (5) with gland seals and plunger spring (7) from body by lightly tapping it on wooden block. ● Remove gland seals from plunger. 10B. INSPECTION AND ASSEMBLY OF SLAVE CYLINDER (Fig.8) ● Examine bore of body. If it is not score, ridged or corroded do not replace. If there is doubt about condition of bore, then it should be replaced with new slave cylinder assembly. Even otherwise if the clearance between the plunger &bore exceeds 0.13 mm. the assembly should be replaced. ● Examine plunger for rust, burrs, and ridges, Replace if necessary. ● Fit new gland seals on plunger such that it fits squarely in plunger groove. ● Fit small end diameter of spring to plunger. ● Lubricate bore of body with brake fluid and dip plunger assembly in it. Insert plunger assembly into bore with bigger end diameter of spring leading. ● Fit washer over push rod and place it over plunger as shown. Fit circlip. ● Check condition of dust cover. If necessary replace. ● Slide dust cover over body. ● Ensure the push rod length from the slave cylinder mounting face is as shown in sketch. 11. INSTALLATION OF CLUTCH ACTUATION MECHANISM ● Install clutch pedal bush if removed earlier, using suitable drift. ● Locate clutch pedal in the mounting bracket properly and insert hex bolt. Note Smear oil on inside surface of clutch pedal bush while assembling. ● Fit and tighten two hex nuts with clutch pedal mounting bolt. Ensure free movement of lever after tightening. ● Locate clutch actuationmechanismproperly.Push the eye end and fit it on the mounting pin at clutch pedal carefully. Install washer and split pin and bend the split pin. ● Mount slave cylinder on clutch housing. Make sure that push rod end is properly located at clutch fork seat. ● Ensure that bleeding screw of slave cylinder is at top. Tighten slave cylinder mounting nuts. ● Install master cylinder on fire wall and tighten its mounting screws. ● Install push rod fork and clutch pedal. Insert clevis pin. Install plain washer and lock clevis pin with split pin. ● Connect pipe connection to slave cylinder. ● Connect pipe connection to master cylinder properly.
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