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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:

Programming Transmitters to the Vehicle
Only RKE transmitters programmed to this vehicle will work. If a transmitter is lost or stolen, a replacement can be purchased and programmed through your dealer. When the replacement transmitter is programmed to this vehicle, all remaining transmitters must also be reprogrammed. Any lost or s ...

Front Bumper Fascia Bracket Replacement
Front Bumper Fascia Bracket Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement. Remove the front bumper fascia center support bracket. Refer to ...

SIR Service Precautions
General Service Instructions Warning: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling . Failure to observe the correct procedure could cause deployment of the SIR components, person ...

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