Help w/clutch master cylinder replacement

Peterism03,

I share your pain! I tried last weekend to change out the clutch MC on my 91 Corolla wagon and gave up just before I got out the crow bars and 10 lb hammers.

Problem #1: can't get a wrench on the fluid line flange nut ... well, actually I can get a stubby 10mm on it, I just can't get it to turn and the corners were starting to round off

Problem #2: The power brake booster reservoir covers the lower flange so that you can't simply remove the master cylinder. Looks like "brute force" or loosening the brake master cylinder/booster assembly enough to get sufficient wiggle room to remove the clutch MC is required.

Problem #3: All the OEM replacement cylinders I've seen have the fluid line on the side, instead of the top, of the MC; thus requiring a new line to be installed.

My latest hare-brained plan is to take my Dremel and use a cut-off wheel to slice off the original mounting bolts at the inside of the firewall so I can get the old one out without dropping out the brake MC; then cut off the old pressure line just above the flange nut - then splice in a new flange end so it can mount at the "new" off-by-90-degrees OEM cylinder; then to mount the new OEM cylinder I'll position it first and then screw in the mounting bolts from the inside of the firewall ... IF I can get in place - looks like the clutch push rod/clevis assembly are "kept" in the MC and non-removable.

All in all, this is one really poor design for R&R of a simple clutch MC.

I registered on this forum just to post my frustration and to hope that some Toyota techie can help us both out.

Tell me about your "brute force" method for removing the old one. Was it fun? Did you get to swear a lot?

-John

Zoni_Camry,

Thanks for the reply/help. Yeah, I hear ya' on the "long way" sometimes being the better way around a problem ... [deep sigh]; I'm just ticked to have to go that route to change out a simple clutch master cylinder! It's been about 25 years since I last turned a wrench as a professional mechanic - I clearly recall cursing automotive design engineers then and the same sensation of steam pouring out of my ears occured again with this little "gotch ya!"

I can get a simple 10mm open end wrench on the fluid line, I just can't bust it loose - the corners of the nut are rounding off as I try it and there's only room to turn the wrench about 3/4" max. So I have to buy myself a 10mm flare nut wrench to get it loose (I think a 10mm crowfoot would just round off the nut also] . Meanwhile I found an online site for original toyota parts that is WAY more reasonable than my local dealership on the master cylinder (OEM "Sorta fits" $40; Dealership $99; Online original design match $55). So, I'm going to find a 10mm flare nut wrench and order an original replacement MC online ... and resign myself to having to pull the Brake MC/booster assembly to do it.

Speaking of Constitutional amendments ... I firmly believe that all automotive engineers should be required to do a "field practicum" of one year in the auto repair business before they are granted a degree ... they always seem clueless to the fact that "somebody" will have to eventually become half contortionist/half magician to actually work on their designs. I think I can get this motion seconded by anyone who's ever tried to track an intermittant dashboard electrical problem, :lol: