GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Sunfire 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Master Cylinder Reservoir Replacement

Removal Procedure
  1. Remove the master cylinder. Refer to Master Cylinder Replacement .
  2. Remove the brake fluid level sensor from the reservoir.

    3. Object Number: 176838 Size: SH
  3. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange.
  4. Carefully tap out the reservoir retaining pins.
  5. Remove the reservoir from the from the master cylinder by pulling the reservoir straight up and away from the cylinder.
  6. Remove the seals from the master cylinder.

Installation Procedure

    Object Number: 744964 Size: SH
  1. Inspect the reservoir (1) for cracks or deformation. If found, replace the reservoir.
  2. Clean the reservoir with denatured alcohol or equivalent.
  3. Lubricate the new seals (2) and outer surface area of the reservoir-to-housing barrels with Delco Supreme 11 (GM P/N 12377967) or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container.
  4. Install the lubricated seals (2), make sure they fully seated.
  5. Install the reservoir (1) to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned.

    6. Object Number: 176838 Size: SH
  6. Carefully tap the reservoir retaining pins into place to secure the reservoir.
  7. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs.
  8. Install the master cylinder. Refer to Master Cylinder Replacement .