REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5 and 6
- Disconnect the negative battery cable.
- Apply the brake pedal several times to exhaust all the vacuum in the system.
- Detach and cap the brake lines from the master cylinder.
- If equipped, detach the brake warning indicator connector.
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 2 nuts and lockwashers 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.
- Install a new seal in the groove in the master cylinder mounting face.
- 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. Tighten the front fitting to 16-21 ft. lbs. (21-29 Nm), and the rear fitting to 10-15 ft. lbs. (15-20 Nm).
- 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.