Service Procedure
1. Remove the brake fluid level switch electrical connector (Figure 1).
2. Place a small drain pan under the master cylinder.
3. Disconnect the brake tubes from the master cylinder and seal off the ends of the brake tubes with plugs.
4. Remove and save the two master cylinder mounting nuts.
5. Remove the original master cylinder and fluid reservoir.
CAUTION:
Use extreme care to avoid spilling brake fluid onto painted
surfaces of the vehicle. Brake fluid may cause paint damage.
6. Transfer the brake fluid strainer located under the original reservoir fill cap to the new master cylinder fluid reservoir.
7. Remove and save the brake fluid reservoir retaining bolt located on the side of the master cylinder body (Figure 2).
8. Discard the original master cylinder and reservoir assembly.
9. Install the new master cylinder fluid reservoir onto the new master cylinder body using the following procedure:
a. Lightly coat the rubber seals in the master cylinder and the fluid ports on the reservoir with DOT 4 brake fluid.
b. Carefully press the brake fluid reservoir onto the master cylinder body (Figure 3).
c. Install the brake fluid reservoir retaining bolt. Tighten the retaining bolt securely (Figure 2).
10. Carefully install the new master cylinder body-to-brake booster rubber o-ring (Figure 2).
11. Bench bleed the new master cylinder using the following procedure:
a. Mount the master cylinder in vise (Figure 4).
b. Attach bleeder tube adapters (Miller Special Tool 8822) into the fluid ports on the master cylinder body (Figure 4).
c. Install bleeder hoses (Miller Special Tool 8358) to the adapters that were installed in Step 11b (Figure 4).
d. Place the open end of the bleeder hoses into a half filled bottle of DOT 4 brake fluid (Figure 4). Be sure that the hose ends are totally submerged in brake fluid.
e. Fill the master cylinder reservoir with fresh DOT 4 brake fluid.
CAUTION:
Use Brake & Clutch Fluid, part number A000989080701, DO NOT USE DOT 3 BRAKE FLUID.
f. Press the master cylinder piston rod inward with a wood dowel. Then release the master cylinder piston rod and allow it to return under spring pressure. Continue the bleeding operation until there are no air bubbles in the brake fluid.
12. With the bleed hoses still attached, install the new master cylinder to the brake booster. Install the master cylinder mounting nuts and tighten the nuts to 20 ft. lbs. (28 Nm).
CAUTION:
Use extreme care to avoid spilling brake fluid onto painted surfaces of the vehicle. Brake fluid may cause paint damage.
13. Remove the front bleed hose and adapter from the front port of the master cylinder.
14. Connect the front brake tube to the front port of the master cylinder and tighten until there is no fluid leaking from the connection.
15. Remove the rear bleed hose and adapter from the rear port of the master cylinder.
16. Connect the rear brake tube to the rear port of the master cylinder and tighten until there is no fluid leaking from the connection.
17. Bleed the brake system using the following procedure:
a. Fill the master cylinder reservoir with DOT 4 brake fluid.
b. Have an assistant pump the brake pedal several times and then press and hold the brake pedal down.
c. While the assistant is holding the brake pedal down, loosen the front master cylinder brake tube nut turn for two seconds and then retighten the tube nut.
d. Repeat Steps 13a through 13c for the rear master cylinder brake tube nut.
18. After both brake circuits have been bled, tighten the master cylinder brake tube nuts to 124 in. lbs. (14 Nm).
19. Remove the small drain pan located under the master cylinder.
20. Reconnect the brake fluid level switch electrical connector.
21. Check brake fluid level and add DOT 4 brake fluid as required.
22. Verify that there are no brake fluid leaks and that the brakes operate properly.