Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement

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

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

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

1. Apply and release the brake pedal 20 times to deplete the hydraulic brake booster accumulator reserve.





Note: Reference mark the brake pipe locations for correct installation.

2. Disconnect the rear and left front brake pipes from the brake master cylinder.
Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.




3. Disconnect the right front brake pipe from the brake master cylinder.
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
4. Disconnect the electrical connectors from the electronic brake control module (EBCM).
5. Disconnect the electrical connector for the fluid level sensor.
6. Remove the knee bolster panel. Refer to Driver Knee Bolster Replacement (Left Hand Drive) (Driver Knee Bolster Replacement)Driver Knee Bolster Replacement (Right Hand Drive) (Service and Repair).
7. Remove the knee bolster bracket. Refer to Driver Knee Bolster Bracket Replacement (Right Hand Drive) (Service and Repair)Driver Knee Bolster Bracket Replacement (Left Hand Drive) (Driver Knee Bolster Bracket Replacement).




8. Remove the clevis pin retainer from the clevis pin.
9. Remove the clevis pin from the master cylinder push rod.





Note: It may be necessary to relocate or remove some of the wiring harness from their retainers to gain enough clearance to remove the mounting nuts for the brake master and or the brake master cylinder itself.

10. Remove the mounting nuts for the brake master cylinder (2).
11. Remove the brake master cylinder with power brake booster and control module assembly (1).

Installation Procedure




1. Install the brake master cylinder with power brake booster and control module assembly (1) to the vehicle.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the mounting nuts for the brake master cylinder (2) and tighten to 27 Nm (20 lb ft).




3. Install the clevis pin to the master cylinder push rod and the brake pedal.
4. Install the retainer to the clevis pin.
5. Install the knee bolster bracket. Refer to Driver Knee Bolster Bracket Replacement (Right Hand Drive) (Service and Repair)Driver Knee Bolster Bracket Replacement (Left Hand Drive) (Driver Knee Bolster Bracket Replacement).
6. Install the knee bolster panel. Refer to Driver Knee Bolster Replacement (Left Hand Drive) (Driver Knee Bolster Replacement)Driver Knee Bolster Replacement (Right Hand Drive) (Service and Repair).
7. Connect the electrical connector for the fluid level sensor.
8. Connect the electrical connectors to the EBCM.




9. Connect the right front brake pipe to the brake master cylinder and tighten the fitting to 19 Nm (14 lb ft.




10. Connect the rear and left front brake pipes to the brake master cylinder and tighten the fittings to 19 Nm (14 lb ft.
11. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment (Adjustments).
12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Pressure with RPO BRM) (Hydraulic Brake System Bleeding (Pressure with RPO BRM))Hydraulic Brake System Bleeding (Pressure without RPO BRM) (Hydraulic Brake System Bleeding (Pressure without RPO BRM))Hydraulic Brake System Bleeding (Manual with RPO BRM) (Hydraulic Brake System Bleeding (Manual with RPO BRM))Hydraulic Brake System Bleeding (Manual without RPO BRM) (Hydraulic Brake System Bleeding (Manual without RPO BRM)).