REMOVAL & INSTALLATION
See Figures 1 through 12
Clean the area surrounding the brake master cylinder prior to removal. This will allow for less chances of dirt entering the system.
Use a clean suction tube (a turkey baster works well) to remove as much fluid as possible from the reservoir.
Disconnect the electrical wiring for the fluid level sensor (if applicable).
Fig. Fig. 1: Brake master cylinder removal and disassembly components-1979-86 models
Fig. Fig. 2: Brake master cylinder removal and disassembly components-1987-93 models
Fig. Fig. 3: Clean the area to prevent contamination of the brake system with dirt
Fig. Fig. 4: Using a turkey baster to remove the brake fluid from the reservoir works well
Fig. Fig. 5: Disconnect the electrical wiring from the master cylinder
Fig. Fig. 6: Place a rag under the lines when removing them for any spilt fluid
Fig. Fig. 7: Some lines are attached with a bolt and washer
Fig. Fig. 8: Loosen and remove the metal lines attached to the master cylinder
Fig. Fig. 9: Inspect the threads of the metal lines and replace if necessary
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.
Using only a wrench of the correct size (no pliers-ever!), carefully disconnect each brake line from the master cylinder. Label each line with a piece of tape. Plug or tape the end of the line to keep dirt and moisture out.
Do not bend or crimp the steel brake lines. Handle them with extreme care! If damaged, they must be replaced.
Remove the nuts holding the master cylinder to the brake booster and remove the cylinder. Some fluid will remain within the cylinder; take care not to spill it on painted surfaces.
Fig. Fig. 10: Remove the mounting nuts holding the brake master cylinder to the power booster
Fig. Fig. 11: Remove the master cylinder from the power brake booster
Install the master cylinder to the brake booster and tighten the nuts to 9 ft. lbs. (12 Nm).
Carefully connect each brake line to its port on the master cylinder. Start each by hand, making sure that the fitting is at 90° to the port before starting to turn it. Once threaded one or two turns by hand, the wrench may be used to tighten each fitting to 15 ft. lbs. (20 Nm).
Do not overtighten the flare nuts. Overtightening will cause damage to the nut and/or the master cylinder!
Connect the wiring to the master cylinder.
Fill the system with clean, fresh brake fluid.
Bleed the brake system at all four wheels.
Fig. Fig. 12: Fill, bleed and top off the system with fresh brake fluid