ES300 1992-1997

Master Cylinder

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Overhaul



Specific to:

Lexus ES250 1990-1991

Lexus ES300 1992-1993

  1. Remove reservoir tank.

    Click image to see an enlarged view

    Fig. Clutch master cylinder-1990-91 models



    Click image to see an enlarged view

    Fig. Clutch master cylinder-1992-93 models

  2.  
  3. Remove push rod and piston.
    1. Using a pin punch and a hammer, drive out the slotted spring pin.

      Click image to see an enlarged view

      Fig. Using a pin punch and a hammer, drive out the slotted spring pin

    2.  
    3. Pull back the boot and, using snap ring pliers, remove the snap ring.

      Click image to see an enlarged view

      Fig. Pull back the boot and, using snap ring pliers, remove the snap ring

    4.  
    5. Pull out the pushrod.
    6.  

  4.  
  5. Remove piston.
    1. Using compressed air, remove the piston from the cylinder.
      NOTE
      Clean the disassembled parts with compressed air.

    2.  

  6.  
  7. Inspect master cylinder bore for scoring or corrosion. If a problem is found, clean or replace the cylinder.
  8.  
  9. Inspect piston and cups for wear, scoring, cracks or swelling. If either one requires replacement, use the parts from the cylinder kit.
  10.  
  11. Inspect push rod for wear or damage. If necessary, replace the push rod.
  12.  
  13. Coat parts with lithium soap base glycol grease, as shown.

    Click image to see an enlarged view

    Fig. Coat parts with lithium soap base glycol grease

  14.  
  15. Insert piston into cylinder.
  16.  
  17. Install push rod assembly with snap ring.
  18.  
  19. Install reservoir tank and tighten to 18 ft. lbs. (25 Nm).
  20.  

Removal & Installation



Specific to:

Lexus ES250 1990-1991

Lexus ES300 1992-1993

  1. Draw out fluid with syringe.
  2.  
  3. Disconnect clutch line tube:
    1. Using SST (SST 09023-00100) or equivalent, disconnect the tube. Use a container to catch the brake fluid.
    2.  

  4.  
  5. Remove instrument lower finish panel, if necessary. Refer to Instrument Panel Removal & Installation in the Body Interior section.
    1. Remove the lower instrument lower finish panel and disconnect the air duct from the instrument lower finish panel.
    2.  

  6.  
  7. Remove clevis pin and clip.
  8.  
  9. Remove mounting nuts and pull out master cylinder.

    Click image to see an enlarged view

    Fig. Clutch master cylinder-1990-91 models



    Click image to see an enlarged view

    Fig. Clutch master cylinder-1992-93 models

  10.  

To install:

  1. Install the master cylinder and tighten the nuts to:

    1990-91 models: 9 ft. lbs. (13 Nm)
     
    1992-93 models: 58 inch lbs. (8 Nm)
     

  2.  
  3. Connect the hydraulic line and tighten the flare nut to 11 ft. lbs. (15 Nm).
  4.  
  5. Connect the pushrod and install the clevis pin.
  6.  
  7. Fill the master cylinder with fluid and bleed the system.
  8.  

 
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