GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Clutch Hydraulic System

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

The clutch hydraulic system used on 1985-94 models is serviced as a complete unit (except 1994 3.1L). It has been bled of air and filled with fluid. Individual components of the system are not available separately.



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Fig. Fig. 1: View of the clutch hydraulic system - 1985-87 vehicles



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Fig. Fig. 2: Clutch hydraulic system - 1988-89 vehicles



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Fig. Fig. 3: Location of the clutch hydraulic system components - 1990 vehicles

1.8L, 2.0L and 2.2L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the hush panel from inside the vehicle.
  4.  
  5. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  6.  
  7. Unfasten the clutch master cylinder retaining nuts at the front of the dash.
  8.  
  9. Remove the slave cylinder or actuator retaining nuts at the transaxle.
  10.  
  11. Remove the hydraulic system as a unit from the vehicle.
  12.  

To install:
  1. Install the new slave cylinder or actuator to the transaxle support bracket aligning the pushrod into the pocket on the clutch fork outer lever. Tighten the retaining nuts evenly to prevent damage to the slave cylinder. Tighten to 14-20 ft. lbs. (19-27 Nm).
  2.  

Do not remove the plastic pushrod retainer from the slave or actuator cylinder. The straps will break on the first clutch pedal application.

  1. Position the clutch master cylinder to the front of the dash. Install the retaining nuts and tighten the nuts evenly to prevent damage to the master cylinder. Tighten to 15-25 ft. lbs. (20-34 Nm).
  2.  
  3. Remove the pedal restrictor from the pushrod. Lube the pushrod bushing on the clutch pedal. Connect the pushrod to the clutch pedal and install the retaining clip.
  4.  
  5. If equipped with cruise control, check the switch adjustment at the pedal bracket.
  6.  


WARNING
When adjusting the cruise control switch, do not exert an upward force on the clutch pedal pad of more than 20 lbs. (89 N) or damage to the master cylinder pushrod retaining ring can result.