Brake Master Cylinder: Service and Repair

Removal

Fig. 2 Master Cylinder Removal:

For the following procedure, refer to Fig. 2.
1. On all models, disconnect level warning switch connector.
2. Draw fluid out of reservoir with syringe.
3. Remove brake lines from master cylinder.
4. Remove three nuts, then the master cylinder and gasket from brake booster.

Disassembly

Fig. 4 Exploded View Of Master Cylinder:

For the following procedure, refer to Fig. 4 for assistance.
1. Remove master cylinder boot.
2. Remove setscrew and then reservoir tank. Remove cap and strainer from reservoir.
3. Remove two grommets. Then place cylinder in vise.
4. On models without TRAC, push piston in and remove stopper bolt.
5. On models with TRAC, push pistons in and remove No. 1 stopper bolt. Then remove No. 2 stopper bolt.
6. On all models, push pistons in and remove snap ring. Then carefully remove No. 1 piston by hand.
7. Place cylinder on edges of two wooden blocks and tap on cylinder until No. 2 piston comes out.

Inspection
Clean parts with compressed air. Inspect cylinder bore for rust and scoring. Also, inspect for wear or damage. Replace if necessary.

Assembly

Fig. 6 Piston Lube Locations:

1. Apply lithium soap base glycol grease to parts indicated by arrows, Fig. 6.
2. Install springs and pistons. Push in pistons and install snap ring.
3. On models without TRAC, push in piston and install stopper bolt over gasket. Torque bolt to 7 ft. lbs.
4. On models with TRAC, push in piston and install No. 1 stopper bolt over gasket. Repeat with No. 2 stopper bolt. Torque bolts to 7 ft. lbs.
5. On all models, install two reservoir grommets.
6. Install reservoir, while pushing down on reservoir, install setscrew. Torque setscrew to 15.2 inch lbs.
7. Install master cylinder boot.

Installation
1. Install master cylinder and new gasket to brake booster using three nuts. Torque bolts to 9 ft. lbs.
2. Connect brake lines to master cylinder.
3. Connect level warning switch connector.
4. On all models, fill brake reservoir and bleed system. Refer to Brakes and Traction Control/Brakes/Hydraulic System/Service and Repair.
5. Check for leaks. Check and adjust brake pedal.