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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:

Menu System
Controls The Push/MENU/TUNE knob, Push/ MENU/TUNE button, and / BACK button are used to navigate the menu system. Push/MENU/TUNE Knob: Turn to: Enter the menu system. Highlight a menu option. Select a value. Push/MENU/TUNE Button: Press to: Select or activate the highlighted men ...

Engine Oil Cooler Outlet Pipe Replacement (LUW)
Engine Oil Cooler Outlet Pipe Replacement Callout Component Name Preliminary Procedure Remove the engine oil cooler pipe. Refer to Engine Oil Cooler Pipe Replacement. 1 Engine Oil Cooler Outlet P ...

Camshaft Cover Installation
Clean the sealing surfaces. Note: The thickness of the sealing bead should be 2 mm (0.0787 in). Apply sealing compound to areas (1) and (2). Refer to Adhesives, Fluids, Lubricants, and Sealers. Note: The installation procedure sho ...

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