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    2002 Oldsmobile Truck Bravada AWD 4.2L SFI DOHC 6cyl

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    1720 S RIDGEWOOD A
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    GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

    Master Cylinder and Reservoir

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    The clutch master cylinder is located in the engine compartment, on the left-side of the firewall, above or near the steering column.

    REMOVAL & INSTALLATION



    1994 Utility Models

    The master cylinder assembly is non serviceable and the entire unit should be replaced as an assembly.

    1. Remove the lower filler panel.
    2.  
    3. If necessary, remove the lower left side air conditioning duct.
    4.  
    5. Unfasten the push rod retainer at the clutch pedal, then disconnect the push rod and washer from the pedal.
    6.  
    7. Using a suitable hydraulic clutch line separator tool such as J-36221 or its equivalent, disconnect the slave cylinder hydraulic line coupling.
    8.  
    9. Disconnect the slave cylinder hydraulic line from the cowl retaining clip.
    10.  
    11. Unfasten the master cylinder retaining nuts and remove the master cylinder from the engine compartment.
    12.  
    13. Unfasten the reservoir bolts and remove the reservoir.
    14.  

    To install:
    1. Place the reservoir in position, install the bolts and tighten them to 25 inch lbs. (2.8 Nm).
    2.  
    3. Pre-fill the master cylinder and bleed it prior to installation.
    4.  
    5. Place the master cylinder into position, install the retaining nuts and tighten them to 13 ft. lbs. (18 Nm).
    6.  
    7. Connect the slave cylinder hydraulic line coupling and attach the line to the cowl retaining clip.
    8.  
    9. Connect the push rod and washer to the clutch pedal, then install and tighten the push rod retainer.
    10.  
    11. If removed, install the lower left side air conditioning duct.
    12.  
    13. Install the lower filler panel.
    14.  
    15. Properly refill the master cylinder reservoir, then bleed the system of air and check for fluid leaks.
    16.  

    1994-95 Pick-Up and 1995 Utility Models

    See Figure 1



    Click image to see an enlarged view

    Fig. Fig. 1: Typical clutch master cylinder mounting-pick-up models

    On the 2.2L engine, individual components of the clutch actuating system (master cylinder/slave cylinder) may not be available for service. If so it is recommended that a complete, pre-filled and pre-bled unit should be installed and NO attempts should be made to disconnect the hydraulic lines.

    1. Disconnect the negative battery cable.
    2.  
    3. Remove lower filler panel from under the dash.
    4.  
    5. If necessary, remove the lower left A/C duct.
    6.  
    7. Remove the pushrod retainer, then disconnect pushrod from clutch pedal.
    8.  

    To expedite the hydraulic clutch bleeding, loose as little fluid as possible when disconnecting hydraulic lines. All openings should be immediately capped or plugged to prevent system contamination or excessive fluid loss.

    1. Disconnect the slave cylinder hydraulic line from the master cylinder. Drive out the retaining pin holding the hydraulic tube to the master cylinder using a 7 / 64 in. (3mm) punch.
    2.  
    3. Remove the master cylinder from the cowl panel by grasping the cylinder body and rotating it about 45 degrees clockwise, then withdrawing it from the opening.
    4.  

    To install:
    1. Hold the master cylinder assembly at a 45 degree angle (as during removal), then install the master cylinder to the cowl by inserting and twisting counterclockwise 45 degrees. Be sure not to over rotate the cylinder assembly or damage will occur.
    2.  

    Use a new retaining pin and quad seal during hydraulic line installation.

    1. Remove the caps, then connect the slave cylinder hydraulic line to the master cylinder assembly.
    2.  
    3. Connect the pushrod to the pedal and secure using the retainer.
    4.  
    5. If removed, install the lower left A/C duct.
    6.  
    7. Install the lower filler panel.
    8.  
    9. Connect the negative battery cable.
    10.  
    11. Properly refill the master cylinder reservoir, then bleed the system of air and check for fluid leaks.
    12.  

    1996-99 Models
    1. Disconnect the negative battery cable.
    2.  
    3. Remove lower filler panel from under the dash.
    4.  
    5. If necessary, remove the lower left A/C duct.
    6.  

    To expedite the hydraulic clutch bleeding, loose as little fluid as possible when disconnecting hydraulic lines. All openings should be immediately capped or plugged to prevent system contamination or excessive fluid loss.

    1. Detach the hydraulic clutch quick-connect from the concentric slave cylinder following 1 of the 2 steps:
      1. Use 2 small prytools at 180 degrees from each other to depress the white plastic sleeve on the quick connect to separate the clutch line from the concentric slave cylinder quick connect.
      2.  
      3. Use special tool J-36221 to depress the white plastic sleeve on the quick connect to separate the clutch line end from the concentric slave cylinder quick connect.
      4.  

    2.  
    3. Disconnect the tubes clips from the wiring harness bracket and sheet metal.
    4.  
    5. Remove the master cylinder from the cowl panel by grasping the cylinder body and rotating it about 45 degrees clockwise, then withdrawing it from the opening.
    6.  

    To install:
    1. Hold the master cylinder assembly at a 45 degree angle (as during removal), then install the master cylinder to the cowl by inserting and twisting counterclockwise 45 degrees. Be sure not to over rotate the cylinder assembly or damage will occur.
    2.  
    3. Connect the clutch line to the slave cylinder. On some 4.3L models, a special band tie is used to attach the tubing to the body.
    4.  
    5. Connect the tubes clips to the wiring harness bracket and sheet metal.
    6.  
    7. Connect the pushrod to the pedal and secure using the retainer.
    8.  
    9. If removed, install the lower left A/C duct.
    10.  
    11. Install the lower filler panel.
    12.  
    13. Connect the negative battery cable.
    14.  
    15. Properly refill the master cylinder reservoir, then bleed the system of air and check for fluid leaks.
    16.  

     
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