REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5 and 6
Before the master cylinder is reinstalled, the brake booster pushrod must be adjusted. This adjustment requires the use of a measuring tool No. 09397-00010 or its equivalent.
- Open the hood and disconnect the level warning switch harness. Disconnect the negative battery cable. Wait at least 90 seconds prior to working on the vehicle if equipped with SRS.
- Remove the cap from the master cylinder and drain the fluid out with the use a turkey baster or similar syringe. Deposit the fluid into a container.
- Disconnect the brake tubes from the master cylinder. Drain the fluid from the lines into the container. Plug the lines to prevent fluid from leaking onto and damaging painted surfaces or the entry of moisture into the brake system.
- Remove the three nuts that attach the master cylinder and 3-way union to the brake booster.
- Remove the master cylinder from the booster studs. Remove and discard the old gasket.
- Clean the brake booster gasket and the master cylinder flange surfaces. Install a new gasket onto the brake booster.
Adjust the length of the brake booster push rod as follows:
- Set the measuring tool (09737-00010 or equivalent) on the master cylinder with the gasket and lower the pin of the tool until it lightly contacts the position.
- Turn the measuring tool upside-down and position it onto the booster.
- Measure the clearance between the booster push rod and the pin head of the tool. There must be zero clearance. To obtain zero clearance, adjust the push rod length until the push rod light contacts the head of the pin.
- Before installing the master cylinder, make sure that the UP mark is in the correct position. Install the master cylinder over the mounting studs and tighten the three nuts to 9 ft. lbs. (13 Nm).
- Connect the tubes to the master cylinder outlet plugs and tighten the union nuts to 11 ft. lbs. (15 Nm).
- Connect the level warning switch wiring.
- Fill the brake fluid reservoir to the proper level with clean brake fluid and bleed the brake system as described in this section.
- Check for leaks. Check and/or adjust the brake pedal.