REMOVAL & INSTALLATION
See Figures 1 through 5
- Disconnect the negative battery cable.
- Apply the brake pedal several times to exhaust all vacuum in the brake booster.
- Disconnect the fluid level indicator connector.
- If equipped with a manual transmission, remove the hose for the hydraulic clutch master cylinder.
- Remove the brake lines from the primary and secondary outlet ports on the master cylinder.
- Remove the 2 nuts securing the master cylinder to the power brake booster.
- Slide the master cylinder forward and remove it from the vehicle.
Prior to installation, bench bleed the new master cylinder as follows:
- Secure the master cylinder in a soft-jawed vise. Be careful not to damage or distort the master cylinder housing.
- Attach short lengths of brake tubing to the master cylinder outlet ports, positioning the ends of the tubing inside the master cylinder reservoir.
- Fill the master cylinder reservoir with fresh clean brake fluid, making sure the ends of the brake tubing are submerged.
- Using a suitable tool to push on the master cylinder piston, stroke the piston in the master cylinder bore until no more air bubbles are seen in the master cylinder fluid reservoir.
- Remove the short lengths of brake tubing and install temporary plugs in the master cylinder cylinder outlet ports, to keep fluid from spilling.
- Reinstall the cap on the fluid reservoir and remove the master cylinder from the vise.
- Position the master cylinder onto the studs of the power brake booster.
- Reinstall the 2 retaining nuts and torque to 15-18 ft. lbs. (21-29 Nm).
- Reinstall the primary and secondary brake lines to the master cylinder outlet ports and torque to 10-18 ft. lbs. (14-22 Nm).
- If equipped with a manual transmission, connect the hose to the hydraulic clutch master cylinder.
- Reconnect the brake warning indicator switch connector.
- Fill the master cylinder with the proper brake fluid to just below the full line.
- Bleed the brake system starting with the right rear wheel and working to the left front. Top off the master cylinder when complete.
- Road test the vehicle and check for proper brake system operation.
- Secure the master cylinder in a bench vise using soft jaws.
- Remove the master cylinder reservoir cap.
- Manufacture or purchase bleeding tubes and install them on the master cylinder as illustrated.
- Fill the master cylinder reservoir with clean, fresh brake fluid until the level is within 0.25 in. of the reservoir top.
Ensure the bleeding tubes are below the level of the brake fluid, otherwise air may get into the system making your bleeding efforts ineffective.
- Use a blunt tipped rod (a long socket extension works well) to slowly depress the master cylinder piston. Make sure the piston travels full its full stroke.
- As the piston is depressed, bubbles will come out of the bleeding tubes. Continue depressing and releasing the piston until all bubbles cease.
- Refill the master cylinder with fluid.
- Remove the bleeding tubes.
- Install the master cylinder reservoir cap.
- Install the master cylinder on the vehicle.