Here's a general outline. Specific steps and torque specifications will vary slightly depending on the transmission type (automatic or manual). Always consult a repair manual specific to your 1998 Pontiac Sunfire for precise instructions and diagrams. A Haynes or Chilton manual is a good investment.
Tools You'll Likely Need:
* Jack and jack stands (crucial for safety!)
* Wheel chocks
* Socket wrench set (metric)
* Wrenches (metric)
* Brake fluid catch container
* New slave cylinder
* Brake fluid (DOT 3 or DOT 4, check your owner's manual)
* Bleeder wrench
* Rags or shop towels
* Possibly a clutch alignment tool (depending on the transmission type)
General Steps (Adapt to your specific Sunfire model and consult your repair manual):
1. Safety First: Engage the parking brake firmly. Chock the wheels. Jack up the car and securely support it on jack stands. Never work under a car supported only by a jack.
2. Drain Some Brake Fluid: Open the brake fluid reservoir cap slightly to allow air to escape as you work. This prevents air from entering the brake system when you remove the old slave cylinder.
3. Access the Slave Cylinder: This usually involves removing parts of the transmission bellhousing. The exact procedure depends on your transmission. You may need to remove the starter motor, parts of the exhaust system, or other components to get sufficient access. Your repair manual will guide you through this.
4. Disconnect the Slave Cylinder: Disconnect the hydraulic line from the slave cylinder. Have your catch container ready to collect the escaping brake fluid.
5. Remove the Slave Cylinder: This usually involves removing bolts securing it to the transmission. Be careful not to damage any surrounding parts.
6. Install the New Slave Cylinder: Before installing, compare the new cylinder to the old one to ensure everything is correct. If applicable, use a clutch alignment tool to correctly position the new slave cylinder during installation. Install the new slave cylinder, tightening the bolts to the manufacturer's specified torque.
7. Reconnect the Hydraulic Line: Carefully reconnect the hydraulic line to the new slave cylinder. Make sure the connection is secure and free of leaks.
8. Bleed the Clutch Hydraulic System: This is absolutely essential to remove any air trapped in the system. Use a bleeder wrench on the bleeder valve located on the slave cylinder. Have a helper pump the clutch pedal while you open and close the bleeder valve to release air bubbles. Repeat until only clear brake fluid is coming out with no air bubbles. Refer to your repair manual for the correct bleeding procedure.
9. Reassemble: Reinstall any components you removed to access the slave cylinder. Ensure everything is properly connected.
10. Check for Leaks: Inspect all connections for leaks.
11. Lower the Vehicle: Carefully lower the vehicle to the ground.
12. Test the Clutch: Start the engine and test the clutch pedal. It should feel firm and engage smoothly. If the clutch pedal feels spongy or there is no engagement, you likely have air in the system and need to bleed it again. If there are any leaks, you'll need to re-inspect your work.
Again, this is a general overview. Use a repair manual specific to your 1998 Pontiac Sunfire for detailed instructions. Incorrect installation could result in brake failure and serious injury. If you are not comfortable with this process, consult a professional mechanic.
