Master Cylinder Replacement (Non-ABS)

REMOVAL PROCEDURE

CAUTION: Refer to Brake Fluid irritant Caution in Service Precautions.

NOTICE: Refer to Brake Fluid Damage to Electrical Connections Notice in Service Precautions.





1. Disconnect the reservoir fluid level connector (2).
2. Clean the reservoir and the master cylinder.
3. Remove the reservoir.
4. Disconnect the brake pipes from the master cylinder.
5. Remove the attaching nuts.
6. Remove the master cylinder from the brake booster.
7. Disassemble, inspect, and reassemble the master cylinder, if necessary.

INSTALLATION PROCEDURE





1. Adjust the booster piston rod.
2. Bench bleed the master cylinder.

NOTICE: Refer to Fastener Notice in Service Precautions.

3. Install the master cylinder (5) to the brake booster. Secure with 2 master cylinder attaching nuts.
^ Tighten the master cylinder attaching nuts to 13 Nm (115 inch lbs.).

4. Connect the hydraulic lines.
^ Tighten the flare nuts to 16 Nm (12.0 ft. lbs.).

5. Install the reservoir.
6. Connect the reservoir fluid level connector.
7. Fill the reservoir.
8. Bleed the hydraulic brake system.
9. Inspect the hydraulic brake system for leaks.
10. Inspect the brake pedal travel.
11. Perform the brake test.