GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Clutch Master and Slave Cylinder Assembly

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For some early model vehicles, the master cylinder and slave cylinders are removed from the vehicle as an assembly. On later model vehicles, the master and slave cylinders can be removed independently of each other.

REMOVAL & INSTALLATION



1985-94 Vehicles
EXCEPT 1992-94 2.3L (VIN D AND A) ENGINES

See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the steering column opening filler/sound insulator from inside the vehicle.
  4.  
  5. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  6.  
  7. Remove the clutch master cylinder attaching nuts at the front of the dash and disconnect the remote fluid reservoir, if equipped.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: View of the remote fluid reservoir

  1. Unfasten the actuator cylinder attaching nuts at the transaxle.
  2.  
  3. Remove the hydraulic system assembly as a unit from the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: View of the clutch actuator (slave cylinder)-model Muncie transaxle shown



Click image to see an enlarged view

Fig. Fig. 3: Clutch actuator location-Isuzu transaxle shown

To install:
  1. Bleed the system, if necessary.
  2.  
  3. Install the actuator cylinder to the transaxle, aligning the pushrod into the pocket on the lever. Tighten the attaching nuts evenly.
  4.  

New actuators are packaged with plastic straps to retain the pushrod. Do not break the strap off; it will break upon the first clutch application.

  1. Install the master cylinder to the front of the dash. Tighten the attaching nuts to 15-18 ft. lbs. (21-25 Nm) evenly to prevent damage. Connect the remote fluid reservoir, if equipped. If equipped with a bleed screw, bleed the system.
  2.  
  3. Remove the pushrod restrictor from the master cylinder pushrod. Lubricate the bushing on the clutch pedal. Connect the pushrod to the pedal and install the retaining clip. If equipped, make sure the cruise control switch is operating properly.
  4.  

When adjusting the cruise control switch, do not use a force of more than 20 lbs. (9 kg) to pull the pedal up, or damage to the master cylinder pushrod retaining ring could result.

  1. Install the steering column opening filler/sound insulator from inside the vehicle.
  2.  
  3. Push the clutch pedal down a few times. This will break the plastic straps on the actuator. Bleed the system.
  4.  
  5. Connect the negative battery cable and check for proper operation.
  6.  

1992-94 2.3L (VIN D AND A) ENGINES

See Figures 4 and 5

  1. Remove the air intake duct from the air cleaner.
  2.  
  3. Disconnect the negative, then the positive battery cables.
  4.  
  5. Remove the left fender brace.
  6.  
  7. Unfasten the battery hold-down clamp bolt, then remove the battery.
  8.  
  9. Detach the Intake Air Temperature (IAT) sensor lead at the air cleaner.
  10.  
  11. Disconnect the Mass Air Flow (MAF) sensor lead.
  12.  
  13. Detach the PCV pipe retaining clamp from the air intake duct.
  14.  
  15. Unfasten the air cleaner bracket mounting bolts at the battery tray.
  16.  
  17. Remove the air cleaner, MAF sensor and air intake duct as an assembly.
  18.  
  19. Disconnect the electrical lead at the washer bottle, then unfasten the attaching bolts and remove the washer bottle.
  20.  
  21. If equipped, remove the cruise control mounting bracket retaining nuts from the strut tower.
  22.  
  23. From inside the vehicle, detach the sound insulator.
  24.  
  25. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  26.  
  27. Unfasten the master cylinder retaining nuts at the front of the dash.
  28.  
  29. Detach the clutch actuator cylinder quick disconnect fitting from the clutch master cylinder line.
  30.  



Click image to see an enlarged view

Fig. Fig. 4: Detaching the actuator cylinder quick-connect fitting from the clutch master cylinder line

  1. Remove the transaxle assembly as outlined earlier in this section.
  2.  
  3. Disconnect the clutch actuator cylinder from the transaxle.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: After removing the transaxle, disconnect and remove the clutch actuator cylinder

To install:
  1. Attach the actuator cylinder to the transaxle. Install the transaxle assembly into the vehicle as outlined in this section.
  2.  
  3. Fasten the clutch actuator cylinder quick disconnect to the clutch master cylinder line.
  4.  
  5. Position the clutch master cylinder to the front of the dash, then secure using the retaining nuts. Tighten the nuts evenly to 15-18 ft. lbs. (21-25 Nm).
  6.  
  7. Remove the pedal restrictor from the pushrod. Lubricate the pushrod bearing on the clutch pedal. Connect the pushrod to the clutch pedal, then install the retaining clip. If equipped with cruise control, check the switch adjustment at the clutch pedal bracket.
  8.  

When adjusting the cruise control switch, do not use a force of more than 20 lbs. (9 kg) to pull the pedal up, or damage to the master cylinder pushrod retaining ring could result.

  1. Install the sound insulator.
  2.  
  3. Bleed the hydraulic system. For details, please refer to the procedure in this section.
  4.  
  5. Install the washer bottle, then attach the electrical connector.
  6.  
  7. Install the air cleaner, MAF sensor and air intake duct assembly.
  8.  
  9. Fasten the air cleaner bracket and MAF sensor mounting bolts.
  10.  
  11. Install the clamp retaining the air intake duct to the throttle body.
  12.  
  13. Fasten the PCV pipe retaining clamp to the air intake duct.
  14.  
  15. Attach the MAF sensor connector, then connect the IAT sensor lead at the air cleaner.
  16.  
  17. Install the battery, secure with the hold-down clamp. Install the left fender brace. Bleed the system.
  18.  
  19. Connect the positive, then negative battery cables.
  20.  
  21. Attach the air intake duct to the air cleaner.
  22.  

1995-98 Vehicles
MASTER CYLINDER

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. From inside the vehicle, remove the sound insulator.
  4.  
  5. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  6.  
  7. Unfasten the clutch master cylinder retaining nuts from the firewall.
  8.  
  9. Remove the remote fluid reservoir.
  10.  
  11. Detach the clutch master cylinder assembly from the actuator assembly, then remove from the vehicle.
  12.  



Click image to see an enlarged view

Fig. Fig. 6: Relation of the clutch master cylinder to the clutch pedal

To install:
  1. Connect the master cylinder to the actuator cylinder assembly.
  2.  
  3. Install the remote fluid reservoir.
  4.  
  5. Fasten the master cylinder retaining nuts at the front of the dash. Tighten the nuts evenly to 18 ft. lbs. (25 Nm).
  6.  
  7. Connect the pushrod to the clutch pedal. If equipped, adjust the cruise control switch as outlined in Chassis Electrical .
  8.  
  9. Install the sound insulator.
  10.  
  11. Bleed the hydraulic system as outlined later in this section.
  12.  
  13. Connect the negative battery cable.
  14.  

CLUTCH ACTUATOR (SLAVE) CYLINDER

On these vehicles, the slave cylinder is located inside the clutch housing, and requires removal of the transaxle for access.

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the master cylinder from the clutch actuator cylinder.
  4.  
  5. Remove the transaxle.
  6.  
  7. Detach the actuator cylinder from the transaxle.
  8.  

To install:
  1. Lubricate the inside of the bearing with clutch bearing lubricant part no. 12345777 or equivalent.
  2.  
  3. Install the actuator cylinder to the transaxle.
  4.  
  5. Install the transaxle as outlined earlier in this section.
  6.  
  7. Connect the master cylinder to the actuator cylinder.
  8.  
  9. Bleed the hydraulic system.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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