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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 726 (CONVENTIONAL BRAKE COMPONENTS)CONVENTIONAL BRAKE COMPONENTSMASTER CYLINDER REPLACEMENT
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Master Cylinder Replacement

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Master Cylinder Replacement
WARNING: This page is about a different car, the 2011 Honda Insight and 2010 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid gets on the paint, wash it off immediately with water.
  • Be careful not to damage or bend the brake lines during removal and installation.
  • Plug the ends of the hoses and joints to prevent spilling brake fluid.
  1. Remove the air cleaner housing cover and the air cleaner housing (see AIR CLEANER REMOVAL/INSTALLATION ).
  2. Remove the reservoir tank cap, then remove the brake fluid from the reservoir tank with a syringe.
  3. Disconnect the brake fluid level switch connector (A).
    Fig 1: Brake Fluid Level Switch Connector And Mounting Bolt With Torque Specification
    G06430711Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Remove the reservoir tank mounting bolt (B) from the bracket (C).
  5. Disconnect the brake lines (A) from the master cylinder (B). To prevent spills, cover the hose joints with rags or shop towels.
    Fig 2: Brake Lines, Master Cylinder And Nuts With Torque Specifications
    G06430712Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Remove the master cylinder mounting nuts (C) and washers (D).
  7. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder.
  8. Remove the rod seal (F) from the master cylinder.
    NOTE: During installation, set the new rod seal onto the master cylinder with its grooved side (G) toward the master cylinder.
  9. Install the master cylinder in the reverse order of removal, and note these items:
    • Coat the inner bore lip and the outer circumference of the new rod seal with the shin-etsu silicone grease (P/N 08798-9013).
    • Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
    • Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary (see BRAKE PEDAL AND BRAKE PEDAL POSITION SWITCH/IDLE STOP SWITCH ADJUSTMENT  ).
  10. Bleed the brake system (see BRAKE SYSTEM BLEEDING  ).
  11. Spin the wheels to check for brake drag.
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.