GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Malibu 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Master Cylinder Replacement

Removal Procedure

    Object Number: 175184 Size: SH
  1. Disconnect the electrical connector from the fluid level switch (2).
  2. Remove the brake pipe tube nuts (3,4) from the master cylinder assembly.
  3. Plug the open brake pipes (3,4) in order to prevent brake fluid loss and contamination.

    4. Object Number: 175182 Size: SH
  4. Remove the master cylinder mounting nuts (5).
  5. Remove the master cylinder (1) from the booster (3).

Installation Procedure

    Object Number: 175182 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the master cylinder (1) to the power booster assembly (3).

    2. Tighten
    Tighten the master cylinder assembly mounting nuts (5) to 27 N·m (20 lb ft).


    Object Number: 175184 Size: SH
  2. Install the brake pipe tube nuts (3,4) to the master cylinder assembly.

    3. Tighten
    Tighten the brake pipe tube nuts to 23 N·m (17 lb ft).

  3. Connect the electrical connector to the fluid level switch (2).

    4. Caution: Brake fluid may be irritating to the skin or the eyes, or may cause nausea, vomiting, or diarrhea if swallowed. In case of contact or swallowing take the following actions:

       • Eye contact - rinse thoroughly with water
       • Skin contact - wash with soap and water
       • If swallowed - Contact a physician immediately. Give two glasses of water and induce vomiting by sticking fingers down the throat.

    Notice: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables, or electric connectors. Brake fluid will damage the paint and the electrical connections. If any fluid is spilled on the vehicle, flush the area to lessen the damage.

  4. Fill the master cylinder to the proper level using clean brake fluid. Refer to Master Cylinder Reservoir Filling .
  5. Bleed the hydraulic system. Refer to Hydraulic Brake System Bleeding .