Pontiac 20762127 Cylinder Assembly, Brake Master

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To remove the brake master cylinder, start by disconnecting the negative battery cable and removing as much fluid as possible from the reservoir. If the vehicle has a manual transaxle, disconnect the clutch fluid hose and plug it or wrap it in a plastic bag. On certain models, remove the cover from the underhood fuse/relay box, the underhood electrical center, and the transmission control module if necessary. Place rags under the fluid fittings and prepare caps or plastic bags to cover the ends of the lines. Loosen the fittings at the ends of the brake lines and plug the ends to prevent contamination. Disconnect the remote brake fluid reservoir hose on ION models and remove the mounting fasteners to detach the remote reservoir. Disconnect the electrical connector at the brake fluid level switch and remove the nuts attaching the brake master cylinder to the power booster. Carefully pull the brake master cylinder off the studs and out of the engine compartment. If installing a new brake master cylinder, transfer the reservoir to the new one after removing the retaining pins. To install the new brake master cylinder, bench bleed it first by mounting it in a vise and attaching bleeder tubes to the outlet ports. Fill the reservoir with brake fluid and slowly push the pistons into the brake master cylinder to expel air. Repeat until no more air bubbles are present, then remove the bleed tubes and install plugs. Install the brake master cylinder over the studs on the power brake booster and tighten the attaching nuts. Thread the brake line fittings into the brake master cylinder by hand and tighten them securely. Connect the brake fluid switch electrical connector and, if applicable, the fluid hose from the clutch master cylinder. Fill the brake master cylinder reservoir with fluid and bleed the brake master cylinder and brake system. Finally, test the operation of the brake system before normal use.