GM Prizm/Nova 1985-1993 Repair Guide

Clutch Master Cylinder

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REPAIR GUIDE TIP:

When inspecting the clutch hydraulic system for leakage or impaired function, check the inside of the firewall (under the carpet) below the clutch master cylinder. A master cylinder leak may not show up under the cylinder on the engine side of the firewall.

REMOVAL & INSTALLATION



1985-93

See Figure 1


CAUTION
The clutch driven disc contains asbestos which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from any clutch area! When cleaning clutch surfaces, use commercially available brake cleaning fluids.

  1. Drain or siphon the fluid from the master cylinder.
  2.  
  3. Disconnect the hydraulic line to the clutch from the master cylinder.
  4.  


WARNING
Do not spill brake fluid on the painted surfaced of the vehicle.

  1. Inside the car, remove the underdash panel and the air duct.
  2.  
  3. Remove the pedal return spring.
  4.  
  5. Remove the spring clip and clevis pin.
  6.  
  7. Unfasten the bolts which secure the master cylinder to the firewall. Withdraw the assembly from the firewall side.
  8.  

To install:
  1. Install the master cylinder with its retaining nuts to the firewall.
  2.  
  3. Connect the line from the clutch to the master cylinder.
  4.  
  5. Connect the clevis and install the clevis pin and spring clip.
  6.  
  7. Install the pedal return spring.
  8.  
  9. Fill the reservoir with clean, fresh brake fluid and bleed the system.
  10.  
  11. Check the cylinder and the hose connection for leaks.
  12.  
  13. Adjust the clutch pedal.
  14.  
  15. Reinstall the air duct and underdash cover panel.
  16.  

OVERHAUL



See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Clutch master cylinder components - 1989-91

  1. Clamp the master cylinder body in a vise with protected jaws.
  2.  
  3. Separate the reservoir assembly from the master cylinder.
  4.  
  5. Remove the snapring and remove the pushrod/piston assembly.
  6.  
  7. Inspect the master cylinder bore for scoring, grooving or corrosion. If any of these conditions are observed, replace the cylinder. Inspect piston, spring, push rod and boot for damage or wear replace any parts which are worn or defective.
  8.  
  9. Before reassembly, coat all parts with clean brake fluid.
  10.  
  11. Install the piston assembly in the cylinder bore.
  12.  
  13. Fit the pushrod over the washer and secure them with the snapring.
  14.  
  15. Install the reservoir and tighten the nut.
  16.  

 
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