Quest 1995-1996

Master Cylinder

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Removal & Installation




WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.


CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

  1. Clean the area around the master cylinder and line connections to keep dirt from getting into the system.
  2.  
  3. Using a flare nut wrench, remove and plug the front and rear master cylinder lines from the master cylinder.
  4.  
  5. Remove and plug the two master cylinder reservoir hoses from the master cylinder.
  6.  
  7. Remove the two master cylinder nuts and remove the master cylinder from the vehicle.
  8.  
  9. If the master cylinder is being replaced and the vehicle is equipped with ABS, remove the dampening valve from the master cylinder where the front master cylinder line connects to the cylinder.
  10.  

To install:

  1. If equipped with ABS, install the dampening valve on the new master cylinder and tighten it to 10 - 16 ft. lbs. (13 - 22 Nm).
  2.  
  3. Position the master cylinder on the brake booster and install the nuts. Tighten the nuts to 6 - 8 ft. lbs. (8 - 11 Nm) on 1993 - 98 vehicles. On 1999 - 00 vehicles, tighten them to 9 - 13 ft. lbs. (12 - 18 Nm).
  4.  
  5. Unplug and install the two master cylinder reservoir hoses to the master cylinder.
  6.  
  7. Bleed the master cylinder as follows:
    1. Manufacture or purchase bleeding tubes. Install them on the master cylinder where the front and rear lines connect. Position the other ends of both tubes in the top of the master cylinder reservoir.
    2.  
    3. Fill the master cylinder reservoir using only new DOT 3 or equivalent brake fluid.
    4.  
    5. Cover the top of the master cylinder reservoir with a clean shop towel.
      NOTE
      Ensure the bleeding tubes are below the level of the brake fluid, otherwise air may get into the system making your bleeding efforts ineffective.

    6.  
    7. As the brake pedal is depressed, bubbles will come out of the bleeding tubes. Pump the brakes until clear, bubble-free fluid flows from both brake tubes.
    8.  
    9. Remove the bleeding tubes.
    10.  

  8.  
  9. Install the front and rear master cylinder lines and temporarily tighten them to 11 - 13 ft. lbs. (15 - 18 Nm).
  10.  
  11. Refill the master cylinder reservoir, as necessary, using only new DOT 3 or equivalent brake fluid.
  12.  
  13. Bleed the lines at the master cylinder as follows:
    NOTE
    An assistant is needed to perform the following procedure.

    1. Have an assistant pump the brake pedal ten times and then hold pressure on the brake pedal.
    2.  
    3. Loosen the rear line flare nut until a stream of brake fluid comes out. Have the assistant maintain pressure on the brake pedal until the flare nut is tightened again.
    4.  
    5. Tighten the flare nut.
    6.  
    7. Have the assistant release the pedal, pump it again ten times, and hold pressure on it.
    8.  
    9. Loosen the rear line flare nut again until a stream of brake fluid comes out.
    10.  
    11. Tighten the flare nut.
    12.  
    13. Repeat the previous three steps until clear, bubble-free fluid comes out from around the flare nut.
    14.  
    15. Tighten the flare nut to 11 - 13 ft. lbs. (15 - 18 Nm).
    16.  
    17. Refill the master cylinder reservoir, as necessary.
    18.  
    19. Repeat this bleeding operation at the front line flare nut.
    20.  

  14.  
  15. Check to make sure that the front and rear master cylinder lines are tightened to 11 - 13 ft. lbs. (15 - 18 Nm).
  16.  
  17. Refill the master cylinder reservoir, as necessary, using only new DOT 3 or equivalent brake fluid.
  18.  
  19. Check for leaks and check the brake pedal for firmness and proper operating height.
  20.  
  21. Road test the vehicle and check the brake system for proper operation.

    Click image to see an enlarged view

    Fig. Master cylinder components

  22.  

 
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