Tracker 2000-2004

Master Cylinder

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Overhaul



  1. Unscrew the top portion of the clutch master cylinder push rod.
  2.  
  3. Remove the nut.
  4.  
  5. Remove the boot.
  6.  
  7. Remove the C-clip.
  8.  
  9. Remove the push rod and washer.
  10.  
  11. Remove the clutch master cylinder piston.
  12.  
  13. Inspect all parts for wear or damage. Replace if necessary.

    Click image to see an enlarged view

    Fig. Clutch master cylinder components exploded view

  14.  

To assemble:

  1. Apply hydraulic clutch fluid to the piston assembly and the cylinder body.
  2.  
  3. Install the piston assembly into the cylinder.
  4.  
  5. Install the push rod and the washer.
  6.  
  7. While pushing down on the piston assembly install the C-clip.
  8.  
  9. Install the boot and the nut and screw on the top portion of the push rod assembly.
  10.  

Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the reservoir cap and take out the fluid.
    WARNING
    Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, suitable containers, and fender covers to prevent brake fluid from contacting these areas. Always re-seal and wipe off brake fluid containers to prevent spills.

  4.  
  5. Remove the push rod clevis pin and the push rod clevis retainer.
  6.  
  7. Remove the master cylinder nut from the inside of the vehicle.
  8.  
  9. Disconnect the clutch fluid pipe from the master cylinder.
  10.  
  11. Remove the master cylinder bolt.
  12.  
  13. Remove the master cylinder assembly and the gasket.

    Click image to see an enlarged view

    Fig. Disconnect the clutch fluid pipe from the master cylinder

  14.  

To install:

  1. Add hydraulic clutch fluid to the master cylinder and bleed the air from the cylinder by tilting the cylinder before you install the assembly.
  2.  
  3. Install the master cylinder assembly and the nut and the bolt and tighten to 10 ft. lbs. (13 Nm).
  4.  
  5. Apply grease to the clevis pin. Using lubricant GM P/N 1051344 (Canadian P/N 993037), or equivalent.
  6.  
  7. Install the clevis pin.
  8.  
  9. Install the clutch fluid pipe.
  10.  
  11. Install the clutch fluid pipe flare nut and tighten to 10 ft. lbs. (13 Nm).
  12.  
  13. Fill the master cylinder with brake fluid and check for brake fluid leakage.
  14.  
  15. Install the retainer.
  16.  
  17. Bleed the air from the system and check for the clutch pedal free travel.
  18.  
  19. Connect the negative battery cable.
  20.  

 
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