Brake Master Cylinder: Service and Repair

Master Cylinder Replacement

NOTICE
^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
^ Be careful not to damage or deform the brake lines during removal and installation.
^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent.

1. Remove the under-hood fuse/relay box mount nut (A) and release the clip (B), then move the underhood fuse/relay box (C) aside.





2. Remove the reservoir cap and the brake fluid from the master cylinder reservoir with a syringe.
3. Disconnect the brake fluid level switch connector (A).





4. Disconnect the brake lines (B) from the master cylinder (C). To prevent spills, cover the hose joints with rags or shop towels.
5. Remove the master cylinder mounting nuts (D) and the washers (E).
6. Remove the master cylinder from the brake booster (F). Be careful not to bend or damage the brake lines when removing the master cylinder.
7. Remove the rod seal (G) from the master cylinder.

NOTE: During installation, set a new rod seal onto the master cylinder with its grooved side (H) toward the master cylinder.

8. Install the master cylinder in the reverse order of removal, and note these items:

^ Coat the inner bore lip and the outer circumference of the new rod seal with the Shin-Etsu silicone grease (P/N 08798-9013).
^ Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary.

9. Install the under-hood fuse/relay box.
10. Bleed the brake system.
11. Spin the wheels to check for brake drag.