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Chevrolet Sonic Repair Manual: Clutch Master Cylinder Replacement

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / Clutch / Clutch Master Cylinder Replacement

Removal Procedure
  1. Remove the battery tray. Refer to Battery Tray Replacement.
  2. Remove as much brake fluid out of brake fluid reservoir as possible.

  3. Remove the clutch master cylinder reservoir hose (1) from the clutch master cylinder.

  4. Unclip the clutch actuator cylinder front pipe from the 2 retainers (1).

  5. Remove the retaining clip (1).
  6. Disconnect the clutch actuator cylinder front pipe (3) from the clutch master cylinder (2).
  7. Remove the brake pedal assembly. Refer to Brake Pedal Assembly Replacement.


    8. Note:

    Press the 2 latches (arrows) together.

  8. Disconnect the push rod retainer (1) from the clutch pedal.

  9. Remove the 2 clutch master cylinder fasteners (1).
  10. Remove the clutch master cylinder from the brake pedal assembly.
Installation Procedure
  1. Install the clutch master cylinder into the brake pedal assembly.

    2. Caution:

    Refer to Fastener Caution.

  2. Install the 2 clutch master cylinder fasteners (1) and tighten to 4.5 Y (40 lb in)

    .



    3. Note:

    An audible click will be heard when the clip is correctly seated.

  3. Connect the push rod retainer (1) to the clutch pedal.
  4. Install the brake pedal assembly. Refer to Brake Pedal Assembly Replacement.


  5. Connect the clutch actuator cylinder front pipe (3) to the clutch master cylinder (2).
  6. Install the retaining clip (1).

  7. Clip the clutch actuator cylinder front pipe into the 2 retainers (1).

  8. Install the clutch master cylinder reservoir hose (1) to the clutch master cylinder.
  9. Install the battery tray. Refer to Battery Tray Replacement.
  10. Bleed the hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding.
  11. Fill the reservoir with GM approved brake fluid from a clean, sealed brake fluid container up to the MAX level.
Hydraulic Clutch System Bleeding
Warning: Refer to Brake Fluid Irritant Warning. Caution: Brake fluid must not come in contact with mineral oils and greases. The smallest amount of such could lead to malfunction or bre ...

Clutch Pedal Position Sensor Replacement
Removal Procedure Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement. Remove the clutch pedal position sen ...

Other materials:

DIC Menu Items
Press MENU to view the DIC menus. Some items display in the upper display area, some in the lower display area, and others use both the upper and lower display areas. Use to scroll through the menu items. Not all items are available on every vehicle. The following is a list of all possible ...

Positive Crankcase Ventilation Pipe Removal
Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3). Note: Move retainer clamp (1) in direction of the arrow. Remove the positive crankcase ventilation pipe from the intake manifold. Loosen the charger air bypass val ...

Output Speed Sensor Replacement
Output Speed Sensor Replacement Callout Component Name Preliminary Procedure Remove the control valve body. Refer to Control Valve Body Replacement. 1 Output Speed Sensor Bolt M6 x 1 ...

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