Master Cylinder Replacement

Master Cylinder Replacement
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).

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

Removal Procedure

1. Apply and release the brake pedal several times until the brake pedal becomes firm to deplete the brake booster vacuum reserve.




2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
3. Without disconnecting the wiring harness connectors, reposition the electrical center and the powertrain control modules from the underhood electrical center bracket and remove the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement (Underhood Electrical Center or Junction Block Bracket Replacement).
4. Disconnect the brake fluid level indicator switch electrical connector.
5. Disconnect the master cylinder secondary brake pipe fitting (1).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




6. Disconnect the master cylinder primary brake pipe fitting (1).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




7. Remove the brake master cylinder nuts (1).




8. Disconnect the master cylinder clutch hose quick connect fitting (1) from the clutch master cylinder, if equipped.
Plug the master cylinder clutch hose and cap the clutch master cylinder inlet port to prevent brake fluid loss and contamination.
9. Remove the master cylinder.




10. Remove the master cylinder to vacuum brake booster seal (1) from the master cylinder.

Installation Procedure

1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (Master Cylinder Bench Bleeding).




2. Install the master cylinder to vacuum brake booster seal (1) to the master cylinder.
Ensure the seal is fully seated in the groove in the master cylinder body.




3. Position the master cylinder to the vacuum brake booster and connect the master cylinder clutch hose quick connect fitting (1) to the clutch master cylinder, if equipped.

Caution: Refer to Fastener Caution (Fastener Caution).




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

Tighten the nuts to 22 Nm (16 lb ft).




5. Connect the master cylinder primary brake pipe fitting (1).

Tighten the fitting to 21 Nm (15 lb ft).




6. Connect the master cylinder secondary brake pipe fitting (1).

Tighten the fitting to 21 Nm (15 lb ft).

7. Install the underhood electrical center bracket and position the electrical center and the powertrain control modules to the electrical center bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement (Underhood Electrical Center or Junction Block Bracket Replacement).
8. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair).