Lumina V6-204 3.4L DOHC (1991)
Clutch Master Cylinder: Service and Repair
Master Cylinder
1.
Disconnect battery ground cable.
2.
Remove sound insulator, then disconnect master cylinder pushrod from clutch pedal.
3.
Remove two nuts attaching master cylinder reservoir to strut tower.
4.
Remove anti-rotational screw located next to master cylinder flange at pedal support plate.
5.
Using wrench flats on front end of master cylinder, twist master cylinder counterclockwise to release twist lock to plate attachment. Do not twist
hose connections on top of master cylinder body.
6.
Remove two nuts attaching clutch actuator to transaxle case, then the actuator from transaxle housing with pushrod attached forward out of pedal
plate.
7.
Pull master cylinder assembly. Lift reservoir off strut tower studs, then remove complete hydraulic assembly from vehicle.
8.
Reverse procedure to install, noting the following:
a. Install master cylinder into opening in pedal plate and rotate 45° by applying torque on wrench flats only.
b. Torque anti-rotational screw to 18 inch lbs.
c. Torque reservoir attaching nuts to 36 inch lbs.
d. Install actuator on transaxle housing. Actuator pushrod busing and retaining straps should be left assembled. Actuator straps will break during
normal operation. Pushrod bushing must enter pocket in internal fork housing as actuator is installed on housing studs.
e. Torque actuator attaching nuts evenly to 18 ft. lbs.
f.
Install new bushing in master cylinder pushrod. Lubricate bushing prior to installation.
g. Connect master cylinder pushrod to clutch pedal, with bushing tangs snapped into pedal pin groove.
h. Press clutch pedal down several times, ensuring pedal effort is normal and firm.
i.
On models equipped with cruise control, adjust cruise control clutch switch.
