W/ 25.4 mm (0.999) Piston Diameter & Brake Servo as a Unit

Brake master cylinder with 25.4 mm (0.999 inch) diameter piston and brake servo, removing and installing as a unit
Special tools and equipment
- Refer to Body and Frame.
- Sealing plugs from repair kit, Part No. 1H0 698 311A
- T10006 Brake pedal release tool

CAUTION: Part numbers are listed here for reference on IV. Always check with your Parts department for the latest information.

Removing
- Remove driver's side storage compartment.
Refer to Body and Frame.





Releasing brake pedal
- Remove brake light switch.

1. Inserting T10006 brake pedal release tool
- Insert the tool from below
2. Release procedures
- Tightly hold brake pedal.
- Lift catches off ball head using a slight pull on tool (arrow -A-).
- Tension tool so catches do not re-engage ball head.
- Pull brake pedal from ball head (arrow -B-).
- Attach bleeder hose and bleeder bottle to left-front brake caliper bleeder screw and open bleeder screw.
- Operate brake pedal to pump out as much brake fluid as possible.
- Close left-front bleeder screw.





- Remove bolt -3- attaching brake fluid reservoir -4-.
- Disconnect harness connector -2- to brake fluid level warning switch.





- On vehicles with manual transmissions, disconnect clutch master cylinder supply hose -1- and seal with plug.

Note:
- Cover plenum to catch any spilled brake fluid.
- The brake fluid reservoir is attached to the master cylinder on the bottom side.

CAUTION: Brake fluid must not be allowed to come into contact with paint work because of its caustic effect.

- Remove brake fluid reservoir by pressing locking catch down and pulling reservoir out of sealing plugs.





- Disconnect brake lines -3- on brake master cylinder and seal brake lines and threaded holes using plugs from repair kit.
- Disconnect vacuum hose -2- from brake servo.
- Remove T45 Torx(R) bolts -1- from brake servo.
- Remove brake servo together with brake master cylinder as a unit.





- Remove nuts -1- attaching brake master cylinder to brake servo.
- Carefully separate brake master cylinder from brake servo.

Note: Pay particular attention to the following when installing:
- Clean any spilled brake fluid from the plenum before installing brake servo and master cylinder.
- When bolting the brake master cylinder to the brake servo make sure pushrod is correctly located in the master cylinder.

Installing
Note the following points:
- Adjust brake light switch. Refer to Brake light switch -F-, adjusting.
- Adjust vent valve for cruise control system. Refer to Cruise Control System (CCS) vent valve, adjusting.

Bleeding clutch hydraulics
- Connect US 1116 brake bleeder but do not switch on yet.
- Open bleeder screw on clutch slave cylinder.
- Attach collector bottle hose.
- Switch on bleeder unit and allow approx. 100 cc (6 oz.) of brake fluid to flow out of clutch slave cylinder.
- Close bleeder screw.
- Bleed brake system.