biosurfer1

Still slowly tackling the clutch hydraulic system and I got stuck trying to remove the master cylinder.

I can't get the darn spring clip off the clevis pin to be able to pull the master cylinder out...any tips or tricks? I have taken out the seat so I can try and slide under there but it's so tight it's almost impossible for me to have two hands, needle nose pliers, a light and manage to see and pull out the clip.

I have removed the black plastic cover so there is a tiny amount of room but doesn't seem to be enough. I have tried with a mirror but once I get my hands in there almost impossible to see....any advice? I ordered some long needle nose pliers to try and help remove a hand but damn this is tough! I can't imagine what installation is going to be like but I'll cross that bridge when I get there.

biosurfer1

Well I was finally able to get that clip off after quite the struggle, but now i'm quite at a loss.

I can barely get the pin holding the clevis in to budge. It moved a tiny bit but i cant get leverage in there without more space and there is a black plastic piece right up against one side and a metal tab that seems to be blocking the pin from coming out, though it's very tight so its close.

Any thoughts? Every thing I have read just says "remove clip and push pin out"? I was able to grab the larger end of the pin and try pulling but it wont move at all, and I can barely get the pliers in there to grab it so any kind of leverage is minimal. I'm really quite frustrated at this point, I can't believe it was designed like this, with basically no room to work and this is just the removal part...trying to get everything re-installed? Not sure I'll ever be able to do that!

thomasmryan

I removed nylon 10mm nuts the electrical cover and did it by feel. there is a little bushing in there that might be catching the clip groove in the pin.

biosurfer1

Thanks...the cover was removed (should be interesting getting those nylon nuts back on) but the pin won't move. I was able to move it a tiny bit by pressing the needle nose pliers against it but it seems stuck.

Should it easily slide out or is it slightly pressed in there? I can see the bushing a little but can't see if it's caught on anything.

thomasmryan

a larger pair of side cutters or dykes might help leverage the head out.

993944S2

I don't know if the 968 is the same as the 944. If it is, you can loosen and pull the entire fuse box from the engine bay and move it just out of the way. The clevis pin assembly is just below it. I did not need to do this but I saw a page yesterday with instructions.

biosurfer1

Well, I finally got the darn thing out this morning. It didn't take brute strength or a special tool. In the end, it just took the right amount of pressure relief on the clutch pedal and it popped out. I was able to slide it back and forth a small amount and maybe that loosened something up but I swear I tried moving the clutch pedal before and got no where.

Oh well, done now and can keep going.

biosurfer1

Does anyone have the part number for the pin and bushing? Mine looks to be ok but while everything is out, might as well replace them.

931guru

944 423 387 00 bolt (pin)

999 166 076 02 safety clip

V2Rocket

968 might be different than 944, but on 944 you can just slide the clevis pushrod out from the MC "accordion" and then line the new MC up on the pushrod when installing.
just reach arm up under dash and push the pushrod through the MC firewall hole before installing new MC

the clevis doesn't need to be touched

ClassJ

I found that out the hard way last week. After pulling the steering wheel so I can get under the dash I realized I did not have to pull the pushrod anyway.