Chevrolet Sonic Repair Manual: Master Cylinder Replacement
- Removal Procedure
-
Warning:
Refer to Brake Fluid Irritant Warning.
Caution:
Refer to Brake Fluid Effects on Paint and Electrical Components Caution.
- Place the ignition switch in the OFF position.
- Remove the battery. Refer to Battery Replacement.
- Disconnect the brake fluid level indicator switch electrical connector.
- Using a suitable suction device, remove and properly discard the brake fluid from the brake master cylinder reservoir.
- On manual transmission equipped vehicles, disconnect the clutch master cylinder reservoir hose. Refer to Clutch Master Cylinder Reservoir Hose Replacement
- Disconnect the master cylinder secondary brake pipe fitting (1).
- Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Disconnect the master cylinder primary brake pipe fitting (1).
- Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Remove the master cylinder nuts (1).
- Remove the brake master cylinder.
- Remove the master cylinder seal (1).
- Inspect the master cylinder seal for damage or deterioration and replace, if necessary.
- Remove the brake fluid level indicator switch, if necessary. Refer to Brake Fluid Level Indicator Switch Replacement.
- Remove the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Replacement.
- Installation Procedure
-
- Install the master cylinder reservoir, if removed. Refer to Master Cylinder Reservoir Replacement.
- Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding.
- Install the brake fluid level indicator switch, if removed. Refer to Brake Fluid Level Indicator Switch Replacement.
- Install the master cylinder seal (1).
- Install the master cylinder to the power vacuum brake booster.
- Install the master cylinder nuts (1) and tighten to 50 Y (37 lb ft)
.
- Connect the master cylinder primary brake pipe fitting (1) and tighten
to 18 Y (13 lb ft)
.
- Connect the master cylinder secondary brake pipe fitting (1) and tighten
to 18 Y (13 lb ft)
.
- On manual transmission equipped vehicles, connect the clutch master cylinder reservoir hose. Refer to Clutch Master Cylinder Reservoir Hose Replacement
- Connect the brake fluid level indicator switch electrical connector.
- Install the battery. Refer to Battery Replacement.
- Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
Caution:
Refer to Fastener Caution.
Master Cylinder Bench Bleeding
Warning: Refer to Brake Fluid Irritant Warning.
Caution: Refer to Brake Fluid Effects on Paint and Electrical
Components Caution.
Secure the mounting flange of the bra ...
Special Tools
Illustration
Tool Number/ Description
CH 28662
J 28662
Brake Pedal Effort Gauge
...
Other materials:
Inflatable Restraint Sensing and Diagnostic Module Programming and Setup
Special Tools
EL-49642 SPS Programming Support Tool
For equivalent regional tools, refer to Special Tools.
Note:
DO NOT program a control module unless directed to by a service procedure
or a service bulletin. If the ECU is not properly configured with the correct
calibration ...
Steering Wheel Straight and Column Locked Caution
Caution: With wheels of the vehicle facing straight ahead, secure
the steering wheel utilizing steering column anti-rotation pin, steering column
lock, or a strap to prevent rotation. Locking of the steering column will prevent
damage and a possible malfunction of the SIR system. The ste ...
Clutch and Differential Housing Disassemble
Special Tools
M-680770 Universal Sliding Mallet
R-0007758 Holding Fixture
R-0407008 Counter Shaft Bearing Remover
R-0407010 Input Shaft Needle Bearing Puller and Driver
R-0407013 Gearshift Device Bushing Puller
R-0007761 Universal Handle for Pullers and Installers
T-0207928 Retai ...
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