REMOVAL & INSTALLATION
See Figures 1 through 5
- Disconnect the negative battery cable and if necessary, remove the battery.
- Apply the brake pedal several times to exhaust all the vacuum in the system.
- If equipped with a Hydro-boost booster, loosen the two power steering fluid line bracket nuts, then remove the bracket.
- If equipped, detach the brake warning indicator connector.
- Detach and cap the brake lines from the master cylinder.
A turkey baster (tapered tube with a squeeze ball on top) works well for removing fluid from the reservoir (see photo).
- Siphon off the fluid from the master cylinder reservoir to minimize spillage when lines are disconnected.
- If applicable, disconnect and cap the Hydraulic Control Unit (HCU) supply hose at the master cylinder reservoir and secure in a position to prevent loss of fluid.
- Unfasten the nuts that attach the master cylinder to the brake booster.
- Remove the master cylinder from the booster by sliding it forward and upward from the vehicle.
- Before installation on models equipped with a brake booster, check the distance from the outer end of the booster assembly pushrod, to the front face of booster assembly and turn the rod adjusting screw until the desired length is achieved. Refer to the accompanying illustration for specifications.
- Position the master cylinder assembly over the booster pushrod and onto the 2 studs on the booster assembly.
- Install the retaining nuts, then tighten to 18-25 ft. lbs. (24-34 Nm).
- Uncap and connect the brake lines to the master cylinder.
- On 1989-93 models, tighten the fittings to 18-25 ft. lbs. (24-34 Nm). On 1994-96 models, tighten the front fitting to 16-21 ft. lbs. (21-29 Nm), and the rear fitting to 10-15 ft. lbs. (15-20 Nm).
- If equipped, uncap and connect the HCU hose to the master cylinder reservoir fitting and secure with a hose clamp.
- If equipped, connect the brake warning indicator.
- Fill the master cylinder with Heavy Duty Brake Fluid C6AZ-19542-AA or equivalent DOT 3 brake fluid from a clean, sealed container. Bleed the entire brake system, as outlined in this section.
- Connect the negative battery cable.
- Operate the brake several times, then check for external hydraulic leaks.