GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Actuator (Slave) Cylinder

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REMOVAL & INSTALLATION



See Figure 1

For 1994 3.1L vehicles, the clutch actuator cylinder can be replaced as a separate assembly.

  1. For the 3.1L engine, remove the air intake duct from the air cleaner.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Detach the master cylinder assembly from the actuator cylinder by disconnecting the hydraulic line.
  6.  
  7. Remove the transaxle assembly, as outlined earlier in this section.
  8.  
  9. Remove the clutch actuator cylinder from the transaxle.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Clutch actuator cylinder mounting - Isuzu transaxle shown

To install:
  1. Lubricate the inside diameter of the bearing with clutch bearing lubricant GM part no. 12345777 or equivalent.
  2.  
  3. Install the actuator cylinder in the transaxle, then install the transaxle assembly.
  4.  
  5. Connect the master cylinder-to-actuator hydraulic line.
  6.  
  7. Bleed the hydraulic system, as outlined later in this section.
  8.  
  9. If removed, install the air intake duct.
  10.  
  11. Connect the negative battery cable.
  12.  

HYDRAULIC SYSTEM BLEEDING



1988-89 Vehicles
  1. Remove any dirt or grease around the clutch master cylinder reservoir cap so that dirt cannot enter the system, then remove the cap and diaphragm.
  2.  
  3. Fill the reservoir to the top step with with Delco Supreme II® GM part no. 1052535, or equivalent approved DOT 3 brake fluid.
  4.  
  5. Fully loosen, but do not remove, the bleeder screw which is located on the slave (actuator) cylinder, next to the inlet connection.
  6.  
  7. Fluid will now flow from the master cylinder to the slave cylinder.
  8.  

It is important that the reservoir remain filled throughout the procedure.

  1. Air bubbles should now appear at the bleeder screw.
  2.  
  3. Continue this procedure until a steady stream of fluid without any air bubbles is present, then tighten the bleeder screw to 17 inch lbs. (2 Nm).
  4.  
  5. Check the fluid level in the reservoir and refill to the proper mark.
  6.  
  7. Fasten the master cylinder reservoir cap.
  8.  
  9. The system is now fully bled. Check the clutch operation by starting the engine, pushing the clutch pedal to the floor, then wait ten seconds and place transaxle in reverse.
  10.  
  11. If any grinding of the gears is noted, air may still be present in the system. The entire bleeding procedure must be repeated.
  12.  

Never under any circumstances reuse fluid that has been in the system. The fluid may be contaminated with dirt and moisture.

1990-94 Vehicles
WITH BLEED SCREW
  1. Remove any dirt or grease around the clutch master cylinder reservoir cap so that dirt cannot enter the system, then remove the cap and diaphragm.
  2.  
  3. Fill the reservoir to the top step with with Delco Supreme II® GM part no. 1052535, Hydraulic Clutch fluid GM part no. 12345347, or equivalent approved DOT 3 brake fluid.
  4.  
  5. Fully loosen, but do not remove, the bleeder screw on the slave cylinder next to the inlet connection.
  6.  
  7. Fluid will now flow from the master cylinder to the slave cylinder.
  8.  

For efficient gravity fill, keep the reservoir filled throughout the procedure.

  1. When a steady stream of fluid without any air bubbles is present, tighten the bleeder screw to 17 inch lbs. (2 Nm).
  2.  
  3. Check the fluid level in the reservoir and refill to the proper mark, then install the master cylinder reservoir diaphragm and cap.
  4.  
  5. The system is now fully bled. Check the clutch operation by starting the engine, pushing the clutch pedal to the floor, then wait ten seconds and place transaxle in reverse.
  6.  
  7. If any grinding of the gears is noted, air may still be present in the system. The entire bleeding procedure must be repeated.
  8.  

Never under any circumstances reuse fluid that has been in the system. The fluid may be contaminated with dirt and moisture.

WITHOUT BLEED SCREW
  1. Remove the actuator (slave) cylinder from the transaxle, as outlined earlier in this section.
  2.  
  3. Loosen the master cylinder mounting attaching nuts to the end of the studs, but do not remove the master cylinder.
  4.  
  5. Remove any dirt or grease around the reservoir cap so dirt cannot enter the system, then remove the cap and diaphragm. Fill the reservoir with an approved DOT 3 brake fluid.
  6.  
  7. Depress the hydraulic actuator cylinder pushrod about 0.787 in. (20.0mm) into the slave cylinder bore and hold.
  8.  
  9. Install the diaphragm and cap on the reservoir while holding the slave cylinder pushrod in as described in the previous step.
  10.  
  11. Release the slave cylinder pushrod.
  12.  

The slave cylinder should be lower than the master cylinder.

  1. Hold the slave cylinder vertically with the pushrod end facing the ground.
  2.  
  3. Press the pushrod into the slave cylinder bore with short 0.390 in. (10.0mm) strokes.
  4.  
  5. Observe the reservoir for air bubbles. Continue until air bubbles no longer enter the reservoir.
  6.  
  7. Install the actuator (slave) cylinder to the transaxle.
  8.  
  9. Tighten the master cylinder attaching nuts to 15 ft. lbs. (20 Nm).
  10.  
  11. Check the fluid reservoir in the clutch master cylinder and add, if necessary. Install the diaphragm and cap to the reservoir.
  12.  
  13. To test the system, start the engine and push the clutch pedal to the floor. Wait 10 seconds and select reverse gear. There should be no gear clash. If clash is present, air may still be present in the system. Repeat bleeding procedure.
  14.  

 
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