GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Firebird 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Master Cylinder Replacement

Removal Procedure

    Object Number: 451525 Size: SH

    Notice: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid.

  1. Remove and discard the brake fluid from the reservoir.

    2. Object Number: 222987 Size: SH
  2. Remove the brake pipes from the master cylinder.
  3. Disconnect the brake fluid level sensor electrical connector.
  4. Remove the master cylinder nuts.
  5. Remove the master cylinder.

Installation Procedure

    Object Number: 222987 Size: SH
  1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding .
  2. Install the master cylinder.

    3. 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.

  3. Install the master cylinder nuts.

    4. Tighten
    Tighten the master cylinder nuts to 29 N·m (21 lb ft).

  4. Install the brake pipes to the master cylinder. Hand tighten the brake pipe fittings.
  5. Place a cloth under the master cylinder brake pipes.
  6. Fill the master cylinder reservoir. Refer to Master Cylinder Reservoir Filling .
  7. Have an assistant depress the brake pedal in order to remove air at the loose brake pipe fittings.
  8. While simultaneously holding the brake pedal depressed, tighten the brake pipe fittings.

    9. Tighten
    Tighten the brake pipe fittings to 32 N·m (24 lb ft).

  9. If the brake pedal remains high and firm, start the vehicle. If the brake pedal still feels firm, test drive the vehicle.

    10. If the brake pedal feels soft or spongy, bleed the entire brake hydraulic system. Refer to Hydraulic Brake System Bleeding .

  10. Remove and properly dispose of the cloth from under the master cylinder.
  11. Connect the brake fluid level sensor electrical connector.