Brake Master Cylinder Adapter Replacement

Brake Master Cylinder Adapter Replacement

Removal Procedure

1. Place the transmission in the PARK or NEUTRAL position.

2. Apply the park brake.

Note:
The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes.

3. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal.

Remove the ignition key.

4. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.





5. Remove the master cylinder nuts (1).

Discard the master cylinder nuts.





6. Without disconnecting the brake pipes, release and carefully position aside the master cylinder (1).

Support the master cylinder with heavy mechanics wire or equivalent.





7. Inspect the master cylinder seal (1) for damage and replace, if necessary.

8. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector.





9. Remove the brake pushrod retainer bolt (1), if equipped.





10. Remove the brake pushrod retainer (1).





11. Slide the stoplamp switch (1) off of the brake pedal pushrod pin while simultaneously disconnecting the brake pushrod.





12. Remove the 4 brake pedal bracket nuts (1).





13. Remove the brake master cylinder adapter (1).

14. Inspect the master cylinder adapter gasket for damage and replace, if necessary.

Installation Procedure





1. Install the master cylinder adapter gasket, if removed.

2. Install the brake master cylinder adapter (1).





Caution:
Refer to Fastener Caution Fastener Caution.

3. Install the 4 brake pedal bracket nuts (1) and tighten to 25 Nm (18 lb ft).





4. Connect the brake pedal pushrod while simultaneously installing the stoplamp switch (1).





5. Install the brake pushrod retainer (1).

Rotate the brake pushrod retainer 360 degrees to ensure the retainer is fully engaged in the brake pedal pushrod pivot pin groove.





6. Install the brake pushrod retainer bolt (1), if equipped and tighten to 10 Nm (89 lb in).





7. Connect the BMC primary piston position sensor electrical connector.

8. Install the master cylinder seal (1), if removed.

Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing.





9. Position the master cylinder (1) to the master cylinder adapter.





10. Install 2 new master cylinder nuts (1) and tighten to 33 Nm (24 lb ft).

11. Inspect the battery state of charge. Refer to Battery Inspection/Test Battery Inspection/Test.

12. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging Procedures.

13. Install a scan tool to the vehicle.

Note:
The ignition switch must remain in the ON position with the engine OFF during this procedure.

14. Turn the ignition ON with the engine OFF.

15. Using the scan tool, perform the following steps:

1. Select Diagnostics

2. Select the appropriate vehicle information

3. Select Chassis

4. Select Electronic Brake Control Module (EBCM)

5. Select Module Setup

6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool