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:
Front Differential Carrier Installation (6T40/45/50)
Front Differential Carrier Installation
Callout
Component Name
1
Final Drive Sun Gear
2
Differential Carrier Assembly
3
Front Differential Carrier Bearing Asembly
...
Transmission Rear Mount Replacement
Removal Procedure
Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
Remove and DISCARD the rear transmission mount bracket
to rear mount through bolt (1).
Remove rear transmission mount to frame bolt (3).
Push and hold ...
Synchronizers Cleaning and Inspection
Note: When servicing the synchronizers, retain them in the order
that they are removed. Mark the parts to ensure the correct position for
inspection and assembly.
Clean all the synchronizer parts in a suitable cleaning
solvent and air dry all the parts.
Inspect the 1 ...
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