Master Cylinder Replacement

Master Cylinder Replacement
Removal Procedure

Caution: Refer to Brake Fluid Irritant Caution in Service Precautions.

Notice: Refer to Brake Fluid Damage to Electrical Connections Notice in Service Precautions.





1. Disconnect the reservoir fluid level connector (2).
2. Clean the reservoir and the master cylinder.
3. Remove the reservoir. Refer to Master Cylinder Reservoir Replacement.





4. If the vehicle has ABS, disconnect the brake pipes (1,4) from the proportioning valve (3).
5. Disconnect the brake pipes from the master cylinder.
6. Remove the nuts that retain the master cylinder to the brake booster.
7. If the vehicle does not have ABS, remove the master cylinder from the brake booster. If the vehicle has ABS, remove the master cylinder with the proportioning valve from the brake booster.
8. If the vehicle has ABS, separate the proportioning valve from the master cylinder. Refer to Proportioning Valve Replacement (ABS).
9. Disassemble, inspect, and reassemble the master cylinder, if necessary. Refer to Master Cylinder Overhaul.

Installation Procedure
1. Adjust the booster piston rod. Refer to the Adjustment Procedure in Vacuum Brake Booster Replacement.
2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding.
3. If the vehicle has ABS, install the proportioning valve to the master cylinder. Refer to Proportioning Valve Replacement (ABS).

Notice: Refer to Fastener Notice in Service Precautions.





4. Install the master cylinder (5) and the 2 nuts to the brake booster.
Tighten the nuts to 13 Nm (115 inch lbs.).
5. Connect the brake pipes.
Tighten the flare nuts to 16 Nm (12.0 ft. lbs.).
6. Install the reservoir. Refer to Master Cylinder Reservoir Replacement.
7. Connect the reservoir fluid level connector.
8. Fill the reservoir. Refer to Master Cylinder Reservoir Filling.
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
10. Inspect the hydraulic brake system for leaks. Refer to Brake System External Leak Inspection.
11. Inspect the brake pedal travel. Refer to Brake Pedal Travel Measurement and Inspection.
12. Perform the brake system vehicle road test. Refer to Brake System Vehicle Road Test.