REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9
- Disconnect the negative battery cable.
- Label and disconnect the brake fluid level sensor electrical harness from the reservoir.
- Clean the outside of the master cylinder thoroughly, particularly around the cap and fluid lines.
- Disconnect and cap the brake fluid lines to prevent dirt from entering the system.
- Remove the master cylinder mounting nuts and lift the master cylinder from the brake booster.
Vehicles with adjustable pushrods will have an adjustable clevis with a locknut at the brake pedal connection under the dashboard.
On vehicles equipped with an adjustable pushrod, adjust the pushrod length.
- Apply approximately 17 in. Hg of vacuum to the brake booster using a hand operated vacuum pump.
- Measure the output rod length from the end of the rod to the front face of the booster, as illustrated.
- The dimension of the rod should be 0.2023-0.2122 in. (8.253-8.323mm).
- Bench bleed the master cylinder assembly prior to installation.
- Install the master cylinder and tighten the mounting nuts to 7-9 ft. lbs. (12-13 Nm).
- Connect the brake lines and tighten to 9-9 ft. lbs. (13-16 Nm).
- Fill the brake system with fresh, clean fluid.
- Bleed the brake system.
- Connect the negative battery cable.
- Connect the brake fluid level sensor electrical harness.
- Check for fluid leaks and verify proper brake system operation.