GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Master Cylinder

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REMOVAL & INSTALLATION



Except Anti-Lock Brakes

See Figures 1, 2, 3, 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Using a suitable tool, (a clean turkey baster works well) drain some of the fluid from the master cylinder reservoir.
  4.  
  5. Unplug the electrical connector from the fluid level sensor on the master cylinder.
  6.  



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Fig. Fig. 1: Detach the fluid level sensor electrical connector

  1. Place a number of cloths or a container under the master cylinder to catch the brake fluid. Disconnect and plug the brake lines from the master cylinder; use a flare nut wrench if one is available.
  2.  


WARNING
Brake fluid eats paint. Wipe up any spilled fluid immediately, then flush the area with clear water.

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Fig. Fig. 2: Placing rags under the brake lines will catch any brake fluid that spills out when the lines are disconnected


  1. Unfasten the nuts attaching the master cylinder to the booster or firewall.
  2.  



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Fig. Fig. 3: Unfasten the attaching nuts, then remove the master cylinder from the vehicle

  1. Remove the master cylinder from its mounting studs and from the vehicle.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Master cylinder mounting - vehicles without ABS



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Fig. Fig. 5: Exploded view of a master cylinder assembly

To install:
  1. Attach the master cylinder to the booster with the nuts. Tighten to 20-30 ft. lbs. (27-45 Nm.).
  2.  
  3. Unplug the lines, then connect them to the master cylinder. Tighten to 10-15 ft. lbs. (13-20 Nm).
  4.  
  5. Attach the fluid level sensor electrical lead.
  6.  
  7. Bleed the brakes, as outlined in this section.
  8.  
  9. Connect the negative battery cable.
  10.  

 
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