GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Tracker - 2WD 🢒 Transmission/Transaxle 🢒 Clutch 🢒 Clutch Master Cylinder Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.

    2. Object Number: 631439 Size: SH
  2. Remove the reservoir cap and take out the fluid.

    3. Notice: Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, suitable containers, and fender covers to prevent brake fluid from contacting these areas. Always re-seal and wipe off brake fluid containers to prevent spills.

  3. Remove the push rod clevis pin (4) and the push rod clevis retainer (5).
  4. Remove the master cylinder nut from the inside of the vehicle.

    5. Object Number: 631442 Size: SH
  5. Disconnect the clutch fluid pipe (1) from the master cylinder.

    6. Object Number: 631439 Size: SH
  6. Remove the master cylinder bolt (6).
  7. Remove the master cylinder assembly (1) and the gasket (2).

Disassemble Procedure

    Object Number: 631445 Size: SH
  1. Unscrew the top portion of the clutch master cylinder push rod (4).
  2. Remove the nut (5).
  3. Remove the boot (6).

    4. Object Number: 460904 Size: SH
  4. Remove the C-clip (1).
  5. Remove the push rod (2) and washer.
  6. Remove the clutch master cylinder piston.
  7. Inspect all parts for wear or damage. Replace if necessary.

Assembly Procedure

    Object Number: 631445 Size: SH
  1. Apply hydraulic clutch fluid to the piston assembly (10) and the cylinder body.
  2. Install the piston assembly into the cylinder.
  3. Install the push rod (9) and the washer (8).

    4. Object Number: 460904 Size: SH
  4. While pushing down on the piston assembly (2) install the C-clip (1).

    5. Object Number: 631445 Size: SH
  5. Install the boot (6) and the nut (5) and screw on the top portion of the push rod assembly (4).

Installation Procedure

    Object Number: 631439 Size: SH
  1. Add hydraulic clutch fluid to the master cylinder and bleed the air from the cylinder by tilting the cylinder before you install the assembly.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the master cylinder assembly and the nut and the bolt (6).

    3. Tighten
    Tighten the nut and bolt to 13 N·m (10 lb ft).

  3. Apply grease to the clevis pin. Using lubricant GM P/N 1051344 (Canadian P/N 993037), or equivalent.
  4. Install the clevis pin (5).
  5. Install the retainer (4).

    6. Object Number: 631442 Size: SH
  6. Install the clutch fluid pipe.
  7. Install the clutch fluid pipe flare nut (1).

    8. Tighten
    Tighten the clutch fluid pipe flare nut to 13 N·m (10 lb ft).

  8. Fill the master cylinder with brake fluid and check for brake fluid leakage.

    9. Object Number: 460891 Size: SH
  9. Bleed the air from the system and check for the clutch pedal free travel. Refer to Hydraulic Clutch Bleeding .
  10. Connect the negative battery cable.