REMOVAL & INSTALLATION
- Disconnect the negative battery cable.
- Remove the master cylinder reservoir cap, then use a clean turkey baster or equivalent to siphon out as much fluid as possible and place in a suitable container. Install the cap.
- Disconnect and plug the lines from the brake master cylinder reservoir.
- Detach the fluid level sensor connector, unfasten the retainers, then remove the master cylinder reservoir.
- For vehicles equipped with manual transaxle, remove the clutch master cylinder reservoir bracket.
- Disconnect and plug the brake lines from the master cylinder.
- Unfasten the master cylinder-to-power booster retaining nuts, then remove the master cylinder from the vehicle.
- Adjust the clearance (A) between the brake booster pushrod and the primary piston as follows:
- Calculate the clearance A from the B, C and D measurements, as shown in the accompanying figure.
A equals B minus C minus D.
- The clearance should be 0.256-0.335 in. (0.65-0.858mm). When brake booster negative pressure 9.7 psi (67 kPa) is applied, then clearance value will become 0.004-0.012 in. (0.1-0.3mm).
- Install the master cylinder to the brake booster, then install the retaining nuts. Tighten the nuts to 7 ft. lbs. (10 Nm).
- Install the master cylinder reservoir, securing the retainers.
- Attach the fluid level sensor connector, then unplug and connect the fluid lines to the reservoir.
- The remainder of installation is the reverse of the removal procedure. Fill the reservoir with the proper type and amount of DOT 3 brake fluid from a fresh, sealed container.
- Bleed the brake system, as outlined later in this section.
- Adjust the brake pedal, as outlined later in this section.
BRAKE PEDAL ADJUSTMENTS
Brake Pedal Height
Measure the brake pedal height from the floor of the vehicle to the upper surface of the brake pedal. The distance should be 6.9-7.1 in (176-181mm). If the brake pedal height is incorrect, adjust as follows:
- Detach the stop lamp switch connector.
- Loosen the locknut on the base of the stop light switch and move the switch to a position where it does not contact the brake pedal.
- Loosen the operating rod locknut. Adjust the height of the brake pedal by turning the operating rod using pliers. Once the desired pedal height is obtained, tighten the locknut on the operating rod.
- Screw the stop light switch until the it contacts the brake pedal stopper. Turn switch in until the brake pedal just starts to move. At this point, return (loosen) the stoplight switch 1 / 2 -1 turn and secure in this position by tightening the locknut. In this position, the distance between the lower stop light switch case and the brake pedal stop should be 0.02-0.04 in. (0.5-1.0mm).
- Attach the electrical connector to the stop light switch.
- Check to be sure that the stop lights are not illuminated with no pressure on the brake pedal.
- Without starting the vehicle, depress the brake pedal. If the brake light switch is properly connected, the brake lights will illuminate.
- With the engine off, depress the brake pedal fully several times to evacuate the vacuum in the booster.
- Once all the vacuum assist has been eliminated, press the brake pedal down by hand and confirm that the amount of movement before resistance is felt is within 0.1-0.3 in. (3-8mm).
- If the free-play is less than desired, confirm that the brake light switch is in proper adjustment.
- If there is excessive free-play, look for wear or play in the clevis pin and brake pedal arm. Replace worn parts as required and recheck brake pedal free-play.