Master Cylinder Replacement

REMOVAL PROCEDURE

CAUTION: Before removing or installing any electrical unit or when a tool or equipment could easily come in contact with "live" exposed electrical terminals, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle or components. Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK" position.

1. Disconnect the negative batted, cable.
2. Clean the reservoir cap.
3. Remove the reservoir cap and siphon the fluid from the reservoir.





4. On Antilock Brake System (ABS) models, remove the one bolt (3) securing the three-way joint and set it aside.





5. Remove the three brake pipe flare nuts (two brake flare nuts on models with ABS) (1) and the brake pipes from the master cylinder.
6. Disconnect the fluid level switch electrical connector.
7. Remove the two master cylinder mounting nuts and washers. Remove the master cylinder and gasket from the vacuum booster.

INSTALLATION PROCEDURE
1. Bench bleed the master cylinder.


NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.





2. Install the master cylinder (2) and the new gasket to the vacuum booster. Secure with two mounting nuts and washers.
^ Tighten the master cylinder nuts to 13 Nm (115.1 inch lbs.).
3. Connect the fluid level switch electrical connector.
4. Connect the brake pipes to the master cylinder. Secure with the flare nuts.
^ Tighten the brake pipe flare nuts to 16 Nm (12 ft. lbs.).





5. On models with ABS, install the three-way joint (2) to the master cylinder. Secure the joint with one bolt.
6. Connect the negative batted cable.
7. Bleed the brake system.