Turn the clutch switch or the pedal stop until the pedal height measures 7.9 in. LOCATE THE MASTER CYLINDER PUSHROD; REFER TO Fig. The height should be 8 in. Locate the master cylinder push rod that attaches to the clutch pedal. Anybody every adjust the length of the pushrod that connects the brake pedal to the master cylinder plunger? NOTE: Do not adjust the pedal height with the pushrod depressed. 1. The master cylinder pushrod that came out is 73mm long - measured middle of bolt hole to front half round tip. (203mm) for 1980-82 models or 7.8 in. ie total length from ball tip to further edge of clevis pin hole,the actual diameter of the clevis pin hole and the length of the fork. To adjust the pushrod to this setting requires taking the side cover from the pedal box to get at the pushrod and its locking nut. What's the maximum distance you can adjust the pushrod? The adjustment is at the clutch operating lever. Hi to all, I just fitted a new brake master cylinder in my Boxster MY02. the master cylinder is connected to the clutch pedal. I can see a rubber boot beside the battery in between the brake booster and firewall, do i need to take this boot off/push back to reveal the pushrod inside?. it only needs adjustment if the clutch pedal has any slop in it. I had the same issue. To measure and adjust master cylinder pushrod length, follow the steps in Skill Drill 31-13: 1. My existing Pedal would not allow the Master Cylinder to have enough range for that, so I made a little extension for the clutch pedal pivot arm last year and got by OK. If the push rod is nonadjustable, use shims between the master cylinder and power booster. Some transverse engines have a self-adjusting ratchet on the clutch pedal. My Elans pedals are both the same position and the cylinders seem original. Loosen the master cylinder pushrod locknut (located at the pedal clevis). Without getting too technical about it, the hydraulic clutch is made up of the master cylinder, slave cylinder, and the clutch work. The way is to change the stroke volume (of hydraulic fluid) produced by the clutch master cylinder by adjusting the screw (covered by a hot-melt glue in later years) located between the clutch lever and the handlebar grip. I had to renew all clutch hydraulics. 4. Having done this it's not too hard, you may find it simpler to unbolt it from the fire wall first, though it's not 100% necessary. thanks gregory the kit had the new bearing and were installed and bleed. I can't, for the life of me, figure out how you are supposed to adjust the rod without the Honda tool. Turn the clutch switch or the pedal stop until the pedal height measures 7.9 in. Brian Buckland writes 80mm from center bolt hole to rear of front push lense. I'm about to install a brand new m.c. I thought that was an easy way to show how much free play there is. Pedal comes up high. 1 & 2. The clutch switch surrounds the rod and has a wire harness plugged into it. When you separate the motor and tranny, you will see it as a unit with the throw-out bearing. The recommended pedal ratio with either a 7/8- or 3/4-inch bore clutch master cylinder is around 6:1, so we would need to drill a new pushrod hole approximately 2.2 inches from the pivot point to get the optimum pedal ratio (13.25 / 2.2 = 6.072). 2. Add to Buddy List. Turn the clutch switch or the pedal stop until the pedal height measures 7.9 in. The hydraulic cylinder is in the bell housing. I went out of town so I didn't get to drive the car around so I'm just now finding the pump up. Using the picture (Fig. Loosen the lock nut on the pushrod. Then back off the switch 1/4 turn to make 0.3 mm (0.01 inch) of clearance between the threaded end and pad. Do I need to change the master cylinder, or can the rod be replaced? Caution: DO NOT extend the rod out too far. Make sure the brake pedal is fully released, not bound up, and adjusted properly. The pushrod seems to have disconnected from the clutch master cylinder. Extending too far out can block the compensating port in the master cylinder. I took a small plastic funnel (the tube portion) that was just big enough to go around the clutch shaft, cut it along the side and slid it on and over the rod. Adjust the pedal height by turning the master cylinder pushrod. 99 F250 w/ 7.3. Loosen the master cylinder pushrod locknut (located at the pedal clevis). I am experiencing the 2G pump up in the clutch. Whenever you depress the clutch, the clutch fluid in the master cylinder is displaced by its push rod and travels through a tube to the slave cylinder. You may just be able to just snap the pushrod back into the master cyl. Members Profile. there were 2 people working on the clutch and in a big hurry so who knows. Shims can be used to adjust the push rod if you can’t do it with the pliers. In this example the bonnet hinges at the front, and the master cylinder is on the front bulkhead. The clutch pedal pushrod basic setting must not be adjusted. I know this has been beaten to death but I am experiencing some issues adjusting my master cylinder. This year I wanted to reduce the MC pushrod angle by removing the extension and went up from a 3/4" to a 7/8" MC. The adjustable master cylinder pushrod is correctly adjusted when the clutch can be released (clutch pedal depressed) to select a gear and while engaged (clutch pedal up) the pushrod is not applying pressure to the hydraulic system. Take the hydraulic line off before you start. Discussion Starter • #1 • Dec 29, 2011. In a hydraulic clutch, however, the problem may lie in the master or slave hydraulic cylinders . To adjust the push rod length, first remove the master cylinder from the power booster. I had my clutch replaced last summer and the master and slave cylinders replaced about 2 weeks ago. Just take off the small plate covering the top (6 screws, IIRC) of the clutch pedal tower and you'll have access (although it's tight) to adjust. If a clutch fails to disengage fully when the pedal is pressed, the problem may be the clutch itself. Push piston back into the slave cylinder to the point where you can reinstall the snap ring. The last two pics are of my brake light switch. Member Sponsor Member Joined: 22 May 2007 Location: BOULDER COLORADO Status: Offline ... Is the piston inside the master cylinder returning all the way back to the retaining ring? Clutch adjustment on a transverse engine can be done under the bonnet. Remove the master cylinder following the specified procedure if still installed on the power booster. a pair of pliers, turn the push rod adjusting not in to shorten and out to lengthen the push rod. SOURCE: Removal of slave clutch master cylinder. dust seal back into master cylinder and it can be pressed in by fingers. the adjustment will only take any slack out of the rod which is moved by the clutch pedal up against the piston of the master cylinder. When you step on the brake pedal the booster diaphragm activates a pushrod that shoves the brake master cylinder piston inward, forcing brake fluid through the lines with high pressure. 3. 4 Posts . 5. TERRY . But the Power Master Cylinder doesn't have a groove to lock the pushrod in so a non-power would work better but everyone I have found also has the pushrod attached and doesn't come out! the adjust ment under the dasy has been taken both ways. After that, I removed the little pin (and the cotter pin) connecting the master cylinder pushrod with the clutch pedal. 2. The procedure is in the Chassis Service Manual to adjust the clearance for the pushrod to master cylinder piston. (203mm) for 1980-82 models or 7.8 in. 3 Posts . can anyone help me with the correct length of the pushrod for the clutch master cylinder on a right hand drive tr6. 4) Adjust the Push Rod – To access the push rod, the cylinder needs to be disconnected first. The next step was to adjust the master cylinder’s pushrod. Adjust the pedal height by turning the master cylinder pushrod. to shorten it. i have taken it in until the adjustment bottoms out against the clutch arm. Has anyone came up with a solution to the crappy clip that ford uses on the clutch master cylinder pushrod… You will need to use pliers for the push rod to be adjusted accordingly. Clutch still works because pushrod is not all of the way out and finds the hole when I press the pedal. • the master cylinder push rod has been adjusted incorrectly. If it's broken inside where the rod goes, you may have to replace the master cyl. My pedal height for the brake was an 1-2" lower than the clutch pedal and felt like it was going to go thru the floor. Discussion Starter • #1 • Apr 17, 2007. Push the rubber boot covering the pushrod back towards the master cylinder to ensure that the pushrod is free of crud and that its locking nut and clevis end are free of rust. Place the O.E. Screw in the brake switch until its plunger is fully depressed (threaded end touching the pad on the pedal arm). The booster increases your foot pressure to force the brake fluid into the calipers and wheel cylinders, which in turn collapse the brake pads, or expand the shoes. Worn or ill-fitting seals may allow hydraulic fluid to leak past the piston in either cylinder, so that the slave piston does not travel far enough to disengage the clutch. • the master cylinder has been replaced. Posted on Aug 13, 2008 I used it to make my brake pedal the same height as my clutch pedal with a Power Master Cylinder after a disc brake conversion. The slave cylinder is bolted to the bell housing, its motion moves the throw out bearing. After the rod has been extended, tighten the locking nut. I had to cut it down a 1/4 inch or so but now my brake and clutch pedal are the same height and work perfectly. The push rod has a nut which can be turned outward or inward to increase or decrease its length. Now install DCR Clutch Pedal Pushrod right through dust seal into piston and attach to clutch pedal and adjust … It comes out after turning it 1/4 turn to the left. Using. ^ Check basic setting (A) and adjust threaded clevis if necessary. • the master cylinder push rod has been removed. The pedal need 1/16" - 1/4" of free travel before push rod … I solved this with a longer rod from a 1977 Bronco. Pedal height is measured from the floorboard to the front of the pedal pad. There's a sentence or two about this in the FSM, saying how there should be 1/16 " freeplay at the pedal. The first pic is of the brake pedal in the returned position and the second pic is with the brake pedal depressed and just starting to push the master cylinder piston. Find Members Posts. This is my first thread and post. I need to adjust the brake master cylinder push rod. The documentation with the booster said to loosen the star nut and then to turn the 17mm nut clockwise or counter clockwise until the pushrod makes contact with be master cylinder piston, then to back off the nut 1/4 to 1/2 turn. If the Series III is the RHD you have in your signature, then you're in luck: there's no need to remove the wing to adjust the master cylinder's pushrod. Send Private Message. Increasing the stroke volume will increase the clutch pushrod stroke distance and consequently the clutch plate separation. Adjust the pedal height by turning the master cylinder pushrod. 2) as reference, extend the push rod to allow for more throw. I'd remove the master cyl from the firewall and investigate further. 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