Brake Master Cylinder: Service and Repair

BRAKE MASTER LESS RESERVOIR TANK CYLINDER SUB-ASSY
REPLACEMENT

1. DRAIN BRAKE FLUID

NOTICE: Wash the brake fluid off immediately if it adheres to any painted surfaces.

2. REMOVE AIR CLEANER CAP SUB-ASSY
3. DISCONNECT CLUTCH RESERVOIR TUBE (M/T TRANSAXLE)
4. REMOVE BRAKE MASTER CYLINDER





a. Disconnect the level warning light switch connector.
b. Using SST, disconnect the 2 brake lines from the brake master cylinder sub-assy.
SST 09023-00100





c. Remove the 2 nuts, and pull out the brake master cylinder sub-assy.
5. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
a. Pull out the reservoir stopper.





b. Remove the brake master cylinder reservoir and 2 grommets.
c. Remove the cap and strainer from the brake master cylinder reservoir.
6. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY





a. Apply lithium soap base glycol grease to the 2 grommets and install them to the master cylinder.
b. Install the cap and strainer to the brake master cylinder reservoir.





c. Install the brake master cylinder reservoir assy with the brake master cylinder reservoir tank stopper.

NOTICE: Install the stopper securely to the groove of the reservoir and master cylinder.

7. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

NOTICE: Adjust the brake booster assy w/o vacuum. (Depress the brake pedal several times with the engine stopped.)

HINT: Adjustment of the brake booster push rod is performed when the brake master cylinder sub-assy is replaced with a new one. The adjustment is not necessary when the brake master cylinder sub-assy is reinstalled and the brake booster assy is replaced with a new one.

a. Apply chalk to the tip of the accessory tool.

HINT: The accessory tool is enclosed with a new brake master cylinder sub-assy.





b. Place the accessory tool on the brake booster assy.
c. Measure the clearance between the brake booster push rod and accessory tool.
Clearance: 0 mm (0 inch)

HINT: Adjust the clearance in the following cases:
^ If there is clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the clearance is too small.
^ If the chalk does not stick to the tip of the brake booster push rod, the clearance is too large.





d. If clearance is not within the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt.
SST 09737-00020

HINT: When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.

8. INSTALL BRAKE MASTER CYLINDER





a. Install the brake master cylinder sub-assy to the booster with the 2 nuts.
Torque: 13 Nm (127 kgf-cm, 9 ft. lbs.)





b. Using SST, connect the 2 brake lines to the brake master cylinder sub-assy.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
c. Connect the level warning light switch connector.
9. CONNECT CLUTCH RESERVOIR TUBE (M/T TRANSAXLE)
10. INSTALL AIR CLEANER CAP SUB-ASSY
11. FILL RESERVOIR WITH BRAKE FLUID
12. BLEED MASTER CYLINDER
13. BLEED BRAKE LINE
14. BLEED CLUTCH PIPE LINE (M/T TRANSAXLE)
15. CHECK FLUID LEVEL IN RESERVOIR
16. CHECK FOR BRAKE FLUID LEAKAGE