REMOVAL & INSTALLATION
See Figures 1, 2 and 3
Service this vehicle with DOT 3 brake fluid from a tightly sealed container. Do not use brake fluid with a lower boiling point than DOT 3 as brake failure could result during prolonged hard braking. Do not use any petroleum-based fluid since seal damage in the brake system will result.
- Disconnect the negative battery cable.
- Detach the brake fluid level sensor connector.
Be sure to clean the master cylinder, brake fluid reservoir and surrounding area so that the hydraulic system does not become contaminated during the removal procedure. Be very careful not to allow brake fluid to accidentally spill out of the reservoir. Brake fluid damages painted surfaces.
- Disconnect the brake lines from the master cylinder. Install plugs at the brake line outlets so that dirt or moisture does not contaminate the hydraulic system.
- Remove the two mounting nuts securing the master cylinder to the booster and remove the cylinder from the mounting studs.
- Remove the master cylinder straight out from the brake booster and out of the vehicle.
Remove the brake reservoir as follows:
- Clean the master cylinder housing and brake reservoir.
- Remove the reservoir caps and empty the reservoir of fluid.
- Position the master cylinder securely in a bench vise.
- Remove the two reservoir retaining pins using a hammer and a small punch.
- Rock the reservoir from side to side and remove the reservoir from the rubber grommets. Do not pry the reservoir off with any tool, or damage to the reservoir will result.
- Remove the rubber master cylinder-to-reservoir grommets.
Install the brake reservoir as follows:
- Install new grommets into the master cylinder housing.
- Lubricate the grommets with clean brake fluid.
- Install the reservoir by rocking back and forth until it is fully seated.
- Install the reservoir retaining pins.
The master cylinder used on this vehicle has outlet ports with ISO style flares and metric threads. Be sure that the bleeding tubes used to bleed the master cylinder are of the correct style flares and metric tube nuts.
Bench bleed the master cylinder as follows:
- With the master cylinder secured in a bench vise, connect bleeding tubes to the ports of the master cylinder. Be sure to position the tubes so the tube outlets will be below the surface of the brake fluid when the reservoir is filled to the proper level.
- Fill up the reservoir with clean, fresh DOT 3 type brake fluid.
- Using a wooden dowel, or equivalent, slowly push in the master cylinder pistons then slowly release the pistons allowing them to return to the released position. Repeat this step several times until all the air bubbles have been expelled from the master cylinder.
- Remove the bleeding tubes from the master cylinder ports, plug the outlets and install cap.
- Install master cylinder to the mounting studs, aligning the pushrod with the master cylinder piston. Install the mounting nuts and tighten to 21 ft. lbs. (28 Nm).
- Connect the brake lines to the ports on the side of the master cylinder. Tighten the brake line fittings at the master cylinder to 13 ft. lbs. (17 Nm).
- Reattach the brake fluid level sensor connector. Connect the negative battery cable.
- Check brake fluid level in reservoir and top off with clean, fresh DOT 3 type brake fluid as required.
- Road test vehicle to verify correct braking operation and no leaks.