Removal and Installation

1. Clean any dirt from around reservoir cap. Remove cap, then drain brake fluid into appropriate container.

Fig. 2 Reservoir Connector Screw Location:

2. Remove reservoir connector screw, Fig. 2, then the reservoir.
3. Disconnect brake lines from master cylinder. Do not allow brake fluid to get on painted surfaces.
4. Remove master cylinder attaching bolts, then the master cylinder.
5. Adjust clearance of booster piston rod to master cylinder piston as follows:
a. Push piston rod several times to ensure reaction disc is in place.
b. Measure with gasket in place on master cylinder and booster at atmospheric pressure.

Fig. 3 Piston Installation:

c. Set measuring tool No. 09950-98210, or equivalent, on master cylinder and push pin until it contacts piston, Fig. 3.

Fig. 4 Piston Rod Length Adjustment:

d. Turn tool upside down and place on booster, Fig. 4. Adjust booster piston rod length until rod end contacts piston head.
6. When adjusted, if negative pressure is applied to booster with engine at idle, piston to piston rod clearance should be as follows:
a. 0.004-0.013 inch 0.10-0.35 mm).
7. Install reservoir on master cylinder, then the reservoir connector screw.
8. Install master cylinder on studs, then the mounting nuts.
9. Connect hydraulic lines.
10. Fill reservoir with brake fluid.
11. Check brake pedal height and pedal travel as outlined under Brake Pedal Assy. Adjustments