Chevrolet Sonic Repair Manual: Clutch Master Cylinder Replacement
- Removal Procedure
-
- Remove the battery tray. Refer to Battery Tray Replacement.
- Remove as much brake fluid out of brake fluid reservoir as possible.
- Remove the clutch master cylinder reservoir hose (1) from the clutch master cylinder.
- Unclip the clutch actuator cylinder front pipe from the 2 retainers (1).
- Remove the retaining clip (1).
- Disconnect the clutch actuator cylinder front pipe (3) from the clutch master cylinder (2).
- Remove the brake pedal assembly. Refer to Brake Pedal Assembly Replacement.
- Disconnect the push rod retainer (1) from the clutch pedal.
- Remove the 2 clutch master cylinder fasteners (1).
- Remove the clutch master cylinder from the brake pedal assembly.
Note:
Press the 2 latches (arrows) together.
- Installation Procedure
-
- Install the clutch master cylinder into the brake pedal assembly.
- Install the 2 clutch master cylinder fasteners (1)
and tighten to 4.5 Y (40 lb in)
.
- Connect the push rod retainer (1) to the clutch pedal.
- Install the brake pedal assembly. Refer to Brake Pedal Assembly Replacement.
- Connect the clutch actuator cylinder front pipe (3) to the clutch master cylinder (2).
- Install the retaining clip (1).
- Clip the clutch actuator cylinder front pipe into the 2 retainers (1).
- Install the clutch master cylinder reservoir hose (1) to the clutch master cylinder.
- Install the battery tray. Refer to Battery Tray Replacement.
- Bleed the hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding.
- Fill the reservoir with GM approved brake fluid from a clean, sealed brake fluid container up to the MAX level.
Caution:
Refer to Fastener Caution.
Note:
An audible click will be heard when the clip is correctly seated.
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:
Clearcoat Repair without Repainting
Repair Procedure
Thoroughly wash the repair area with Liquid Wash and Wax GM?€‰P/N?€‰1052870
or the equivalent.
Environmental damage may be corrected. Refer to Environmental Fallout
(Acid Rain) or Rail Dust Damage Repair.
Important: Follow all of the instruc ...
Seat Belt Service Precautions
Note: If the vehicle has been in a collision, refer to Repairs
and Inspections Required After a Collision for additional information.
Do not bleach or dye the seat belt webbing. Use only the following items
in order to clean the seat belt webbing:
A mild soap and water ...
Main Shaft Disassemble (Gen 2)
Special Tools
69604356 Gear Pullers
For equivalent regional tools, refer to Special Tools.
Remove the 1st gear thrust washer (1) and the 1st gear (2)
using 69604356 pullersand a hydraulic press.
ii
Remove the following components:
1st gear bearing asse ...
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