Pontiac Fiero 1984-1988 Repair Guide

Clutch Master Cylinder

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REMOVAL & INSTALLATION





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Fig. Fig. 1 Clutch master cylinder, pedal and linkage components



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Fig. Fig. 2 Use a flare nut wrench to loosen the clutch master cylinder hydraulic line ...



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Fig. Fig. 3 ... then remove the line from the master cylinder



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Fig. Fig. 4 Remove the clutch master cylinder retaining bolts ...



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Fig. Fig. 5 ... then remove the clutch master cylinder from the vehicle



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Fig. Fig. 6 Location of the bleeder screw on the slave cylinder



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Fig. Fig. 7 Attach a clear piece of plastic hose to the slave cylinder bleeder screw and submerge the other end in a container of brake fluid

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Disconnect the cylinder pushrod at the clutch pedal.
  4.  
  5. Disconnect and plug the hydraulic line at the master cylinder.
  6.  
  7. Remove the nuts attaching the cylinder to the cowl, then remove the cylinder.
  8.  

To install:

  1. Position the cylinder pushrod through the cowl and loosely install the cylinder-to-cowl nuts.
  2.  
  3. Connect the cylinder pushrod to the clutch pedal with the spring clip.
  4.  
  5. Tighten the cylinder-to-cowl nuts to 13 ft. lbs. (17 Nm).
  6.  
  7. Connect the hydraulic line to the master cylinder and torque it to 13 ft. lbs. (17 Nm).
  8.  
  9. Fill the clutch master cylinder with the recommended fluid.
  10.  


WARNING
Do not use mineral or parafin base oils in the clutch hydraulic system. These fluids may cause damage to the internal rubber parts. When adding fluid to the system after service operations use GM Delco Supreme No. 11 brake fluid or an equivalent fluid that meets DOT 3 specifications.

Clutch System Bleeding:

  1. When the hydraulic portion of the clutch system has been opened, air enters the system and has to be removed before proper operation can be restored. Use the following procedures to bleed the clutch hydraulic system.
  2.  
    1. Fill the fluid reservoir directly from a can of unused Delco Supreme No. 11 brake fluid or equivalent. Do not use the old fluid because old fluid is contaminated with moisture and dirt which may damage the hydraulic system.
    2.  


Make sure the fluid reservoir is kept full of fluid. If not, air will be pulled into the system when the reservoir runs out of fluid.

    1. Remove the floor mat or any other object that may obstruct the full stroke of the clutch pedal.
    2.  
    3. Unscrew the bleeder screw at the slave cylinder enough to allow fluid to be pumped out ( 1 / 2 - 1 full turn).
    4.  
    5. Push the clutch pedal down through the full stroke.
    6.  
    7. Have an assistant close the bleeder while the pedal is still fully extended. Allow the pedal to return quickly to its stop (with the bleeder Closed).
    8.  
    9. Repeat this procedure until no air bubbles can be seen in the fluid.
    10.  


OVERHAUL



Disassembly


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Fig. Fig. 8 Exploded view of the clutch master cylinder components

  1. Unscrew the filler cap and drain the excess fluid.
  2.  
  3. Pull back the dust cover.
  4.  
  5. Remove the circlip together with the retaining washer and pushrod.
  6.  
  7. Shake the cylinder to eject the plunger assembly.
  8.  
  9. Remove the spring and retainer from the plunger. Compress the spring to free the valve stem from the key hole of the spring retainer.
  10.  

Remove the seal carefully from the plunger not to damage the plunger surfaces.

Assembly
  1. Replace all serviceable seals and parts. Clean the remaining parts thoroughly with denatured alcohol and place them on a clean piece of paper. Examine the bore of the cylinder for visible signs of scores and ridges. If these conditions are excessive, the cylinder will have to be replaced.
  2.  
  3. Install the plunger seal to plunger.
  4.  
  5. Fit the valve seal with the smallest diameter leading to the valve head.
  6.  
  7. Position the spring washer on the valve stem so that it flares away from the valve stem shoulder. Then install the valve spacer and springs.
  8.  
  9. Fit the spring retainer to the spring and compress the spring until the valve stem passes through the key hole slot and engages in the center.
  10.  
  11. Lubricate the seal with DOT 3 brake fluid and insert the plunger into the cylinder with the valve end leading.
  12.  
  13. Position the pushrod and retaining washer into the cylinder and secure the circlip.
  14.  
  15. Lubricate the inside of the dust seal with Silicone Lubricant No. 5459912 or equivalent and install the dust seal.
  16.  
  17. Install the filler cap and remount the cylinder assembly to vehicle as outlined in the previous section. Bleed the system as outlined in the "Clutch System Bleeding" procedures in this section.
  18.  

 
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