GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Spark 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Master Cylinder Overhaul

Disassembly Procedure

    Caution: Refer to Brake Fluid Irritant Caution in the Preface section.


    Object Number: 1282351 Size: SH
  1. Remove the master cylinder. Refer to Master Cylinder Replacement .
  2. Remove the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement .
  3. Remove the reservoir seals (1).
  4. Remove the washer (2).
  5. Remove the stop pin (3).

    6. Object Number: 1282354 Size: SH
  6. Remove the boot (1).

    7. Notice: When removing the retaining ring, avoid damaging the piston or the cylinder wall.

  7. Remove the retaining ring (2).
  8. Remove the primary piston (3).
  9. Carefully remove the secondary piston assembly and the spring from the master cylinder bore (4).

Assembly Procedure

    Object Number: 1282370 Size: SH
  1. Install the secondary piston assembly.
  2. Install the stop pin.
  3. Install the primary piston.
  4. Install the retaining ring.
  5. Install the boot.
  6. Install the washer.
  7. Install the reservoir seals.

    8. Caution: Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid could result in damage to components, or loss of braking, with possible injury.

  8. Install the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement .
  9. Install the master cylinder. Refer to Master Cylinder Replacement .

    10. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:

       • Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.
       • The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents.
       • The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer.
       • Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
       • Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components.
    Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents.

  10. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  11. Bleed the braking system.
  12. Lower the vehicle.