REMOVAL & INSTALLATION
See Figures 1 through 5
Care should be employed when removing the brake master cylinder to not scratch the exposed primary piston.
- Disconnect the negative battery cable.
- Detach the wiring harness from the low fluid level warning switch in the brake master cylinder reservoir, if equipped.
- Detach the brake warning lamp connector from the master cylinder.
- If equipped, disconnect the brake pressure differential valve warning lamp switch from the combination valve.
- Disconnect the hydraulic lines from the brake master cylinder. Plug the hydraulic brake fluid lines to keep dirt, water or other contaminants from entering the system.
- Remove the nuts retaining the master cylinder and bracket holder to the brake power booster, then remove the master cylinder from the vehicle by pulling it straight forward.
- Before installing the master cylinder, adjust the booster assembly pushrod as described earlier in this section.
DO NOT assemble the brake master cylinder to the power brake booster without the square section interface seal.
- Position the master cylinder assembly over the booster pushrod and onto the two power booster studs. Install the attaching nuts to 12-20 ft. lbs. (17-27 Nm).
- Reattach the various wiring connectors.
- Remove the hydraulic fluid line plugs.
- Loosely connect the hydraulic brake system lines to the master cylinder. Fill the master cylinder reservoir with DOT 3 brake fluid to the FILL line on the side of the master cylinder. Bleed the air from the master cylinder and the entire hydraulic system. For more details on bleeding the hydraulic system and master cylinder, refer to the bleeding procedures located later in this section.
- Tighten all hydraulic lines.
- Make sure the master cylinder reservoir is filled to the proper level, then install the cap diaphragm.