Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement (RHD)

Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement (RHD)

Removal Procedure
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .


1. Apply and release the brake pedal at least 20 times to release the power brake accumulator reserve pressure.
2. Mark the location of the brake pipes to the master cylinder.




3. Disconnect the 4 brake pipe fittings from the master cylinder.
Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.




4. Disconnect the brake fluid level sensor (1) electrical connector.
5. Disconnect the electrical connectors (2) and (3) at the brake pressure modulator valve (BPMV) and module assembly.
6. Remove the driver knee bolster bracket. Refer to Driver Knee Bolster Bracket Replacement (Left Hand Drive) (Driver Knee Bolster Bracket Replacement (Left Hand Drive))Driver Knee Bolster Bracket Replacement (Right Hand Drive) (Driver Knee Bolster Bracket Replacement (Right Hand Drive)) .




7. Remove the retainer (1) from the clevis pin.
8. Remove the clevis pin (2) from the master cylinder pushrod and the brake pedal.




9. Remove the 4 master cylinder nuts (1).
Reposition any wiring harnesses as necessary to improve access to the master cylinder nuts.




10. Remove the master cylinder with power brake booster assembly.



Installation Procedure





1. Install the master cylinder with power brake booster assembly.

Notice: Refer to Fastener Notice (Fastener Notice) .





2. Install the 4 master cylinder nuts (1).

Tighten the nuts to 27 N.m (20 lb ft).

3. Position any wiring harnesses which were moved to access the master cylinder nuts to the retainers.




4. Install the clevis pin (2) to the master cylinder pushrod and the brake pedal.
5. Install the retainer (1) to the clevis pin.
6. Verify the correct installation of the retainer by rotating the retainer 360 degrees.
The retainer must rotate freely and not become disengaged from the groove in the clevis pin.
7. Install the driver knee bolster bracket. Refer to Driver Knee Bolster Bracket Replacement (Left Hand Drive) (Driver Knee Bolster Bracket Replacement (Left Hand Drive))Driver Knee Bolster Bracket Replacement (Right Hand Drive) (Driver Knee Bolster Bracket Replacement (Right Hand Drive)) .




8. Connect the brake fluid level sensor (1) electrical connector.
9. Connect the electrical connectors (2) and (3) at the BPMV and module assembly.




10. Connect the 4 brake pipe fittings to the master cylinder.

Tighten the fittings to 19 N.m (14 lb ft).

11. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment (Adjustments) .
12. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment (Adjustments) .
13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual without RPO BRM) (Hydraulic Brake System Bleeding (Manual without RPO BRM))Hydraulic Brake System Bleeding (Manual with RPO BRM) (Hydraulic Brake System Bleeding (Manual with RPO BRM))Hydraulic Brake System Bleeding (Pressure without RPO BRM) (Hydraulic Brake System Bleeding (Pressure without RPO BRM))Hydraulic Brake System Bleeding (Pressure with RPO BRM) (Hydraulic Brake System Bleeding (Pressure with RPO BRM)) .