Overhaul

WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.

MASTER CYLINDER REMOVAL
1. Raise and support the hood.
2. Disconnect the battery ground cable.
3. Disconnect the brake fluid level warning switch electrical connector.
4. Disconnect the two brake tubes and plug the tubes and the brake master cylinder ports.
5. On M/T vehicles, disconnect the hydraulic clutch tube from the brake master cylinder reservoir.
6. Remove the two brake master cylinder nuts.
7. Remove the brake master cylinder.

DISASSEMBLY
1. Clean the outside of the brake master cylinder.
2. Support the brake master cylinder body in a vice.
3. Remove the reservoir cap.
4. Use a suitable suction device to drain the brake master cylinder reservoir.
5. Carefully pry up on the brake master cylinder reservoir to remove.





6. If equipped, remove the two brake pressure control valves.





7. Depress the (A) primary piston and remove the (B) snap ring.
8. Remove and discard the primary piston assembly (2).

Master Cylinder. Piston Assembly Removal:

9. Plug the rear outlet port (1).

WARNING: USE ONLY AS MUCH COMPRESSED AIR AS NECESSARY TO REMOVE THE PISTON. EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE CALIPER BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT COMES OUT OF THE BORE.

10. Apply compressed air into the front outlet port (2) and remove and discard the secondary piston assembly.

NOTE: If the brake master cylinder bore is damaged, the brake master cylinder must be replaced.

11. Use isopropyl alcohol to clean the brake master cylinder bore and inspect for damage or excessive wear.

ASSEMBLY
1. Use clean High Performance DOT-3 Brake Fluid to lubricate the new piston assembly seals and the brake master cylinder bore.

Master Cylinder. Pistons:

2. Carefully install the secondary piston assembly.
3. Carefully install the primary piston assembly.
4. Depress the primary piston.
5. Install the snap ring.
6. If equipped, install the two brake pressure control valves. Tighten to 44-54 Nm (33-39 ft.lbs)
7. Lubricate the two reservoir grommets with DOT 3 Brake Fluid and insert the grommets into the brake master cylinder.
8. Press the brake master cylinder reservoir into the grommets until it snaps in securely.
9. Bleed the brake master cylinder.

MASTER CYLINDER INSTALLATION
NOTE: Tighten mounting nuts to 10-16 Nm (8-12 ft.lbs)
NOTE: Tighten brake line nuts to 13-22 Nm (10-16 ft.lbs)
NOTE: Tighten brake line nuts to 13-22 Nm (10-16 ft.lbs)

- To install, reverse the removal procedure.
- Bleed the brakes. Refer To Brakes - Service and Repair.