Brake Master Cylinder: Adjustments

Pushrod Clearance Adjustment

NOTE: Master cylinder pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder.





1. Set the special tool on the master cylinder body; push in the center shaft until the top of it contacts the end of the secondary piston by turning the adjusting nut.

NOTE: '96 - 97 models shown.

2. Without disturbing the center shaft's position, install the special tool upside down on the booster.
3. Install the master cylinder nuts, and tighten them to the specified torque.
4. Connect the booster in-line with a vacuum gauge 0 - 101 kPa (0 - 760 mm Hg, 30 inch Hg) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mm Hg, 20 inch Hg) vacuum.





5. With a feeler gauge, measure the clearance between the gauge body and the adjusting nut as shown.

NOTE: If the clearance between the gauge body and adjusting nut is 0.2 mm (0.008 inch), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.2 mm (0.008 inch) or more. Therefore it must be adjusted and rechecked.





6. If the clearance is incorrect, remove the tool, and adjust the clearance by holding the pushrod and turning the adjuster in or out.

CAUTION: Do not pull the pushrod out of the brake booster.

NOTE: Adjust the clearance while the specified vacuum is applied to the booster.





7. Adjust the pushrod length as shown if the booster, if the booster is removed.
8. Install the master cylinder.