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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1279 (Manual Transmission Clutch System) >> Repair Instructions >> Clutch Master Cylinder Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Clutch Master Cylinder & Dash Panel
    GM71476Courtesy of GENERAL MOTORS CORP.
  1. Install the clutch master cylinder and the reservoir into position.
  2. Install the clutch master cylinder to the dash panel.
    1. Orientate the clutch master cylinder at a 45 degree angle.
    2. Insert the clutch master cylinder into the dash panel.
    3. Rotate the master cylinder counterclockwise to secure.

      DO NOT over-rotate the master cylinder.

  3. Install the clutch master cylinder reservoir into position.
  4. Install the clutch master cylinder reservoir push-in fasteners.
  5. Install the windshield washer solvent container. Refer to Washer Solvent Container Replacement in Wipers/Washer Systems.
    6. Fig 2: Identifying White Circular Release Ring On The Actuator Hose
    GM71472Courtesy of GENERAL MOTORS CORP.
  6. Raise the vehicle.
    7. IMPORTANT: DO NOT rely on an audible click or a visual verification of the clutch hydraulic hose quick connect fitting connection.
  7. Connect the clutch actuator cylinder hose to the clutch master cylinder hose.

    Push together the clutch hydraulic hose quick connect fittings, then pull back on the fittings to verify engagement.

  8. Check the clutch hydraulic hoses for twists or kinks.
    9. Fig 3: Clutch Actuator Cylinder Hose
    GM71473Courtesy of GENERAL MOTORS CORP.
  9. Install the clutch actuator cylinder hose to the hose retaining clip, at the rear of the engine.
  10. Lower the vehicle.
    11. Fig 4: View Of Master Cylinder Push Rod To Clutch Pedal
    GM71474Courtesy of GENERAL MOTORS CORP.
  11. Install the clutch master cylinder rod to the clutch pedal.
  12. Install the clutch master cylinder rod retainer.
  13. Install the left I/P lower insulator panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gages and Console.
    14. NOTE: Refer to Fastener Notice in Cautions and Notices.
  14. Connect the negative battery cable.

    Tighten:  Tighten the negative battery cable bolt to 15 N.m (11 lb ft).

  15. Program the transmitters. Refer to Transmitter Programming in Keyless Entry.
  16. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding .
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