Brake Master Cylinder: Service and Repair

Master Cylinder And Brake Booster Exploded View:

CAUTION:
^ Be careful not to bend or damage the brake pipes when removing the master cylinder and booster.
^ Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
^ To prevent spills, cover the hose joints with rags or shop towels.
^ Before reassembling, check that all parts are free of dust and other foreign particles.
^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
^ Do not mix different brands of brake fluid as they may not be compatible.
^ Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid.
^ When connecting the brake pipes, make sure that there is no interference between the brake pipes and other parts.
^ Do not disassemble master cylinder or booster. Replace them as complete assemblies.

1. Drain the brake fluid from the master cylinder.
2. Disconnect the brake fluid level switch connectors.
3. Disconnect the brake pipes from the master cylinder.
4. Remove the master cylinder mounting nuts and the master cylinder.
5. Disconnect the vacuum hose from the booster and remove the vacuum hose bracket.
6. Remove the throttle/cruise control cable bracket, then remove the throttle cable grommet from the engine compartment bulkhead.
7. Remove the intake air temperature sensor from the intake manifold.
8. Loosen the pushrod locknut, and remove the cotter pin and joint pin.
9. Remove the booster mounting nuts and clevis.

Brake Booster Removal:

10. Remove the brake booster as follows:
^ Pull the brake booster forward, then turn it to the right until the operating rod is clear of the bulkhead as shown below.
^ Move the operating rod beyond the left damper base by turning the brake booster.
^ Continue to turn the brake booster until the operating rod points forward.
^ Remove the brake booster from the engine compartment with the front cylinder shell side of the brake booster upward.
11. Install the brake booster and master cylinder in the reverse order of removal.

NOTE: Before installing the master cylinder, check and adjust the pushrod clearance, refer to Brakes and Traction Control/Brakes/Hydraulic System/Brake Booster/Vacuum Brake Booster/Adjustments.

12. After installation, check and adjust the brake pedal height, refer to Brakes and Traction Control/Brakes/Hydraulic System/Brake Pedal Assy/Adjustments.
13. Fill and bleed the brake system, refer to Brakes and Traction Control/Brakes/Service and Repair.