REMOVAL & INSTALLATION
On vehicles equipped with an air bag system, work must be started at least 90 seconds after the ignition switch is turned to the lock position and the negative battery cable is disconnected.
Before the master cylinder is reinstalled, the brake booster pushrod must be adjusted. This adjustment requires the use of factory special tool SST No. 09737-00010 or its equivalent.
- Open the hood and disconnect the level warning switch connector. Disconnect the negative battery cable.
- 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 special tool on the master cylinder with the gasket and lower the pin of the tool until it lightly contacts the piston. Turn the special 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 just 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 torque the union nuts to 11 ft. lbs. (15 Nm).
- Connect the level warning switch connector.
- 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.
- Remove the master cylinder from the vehicle.
- Remove the setscrew, if equipped, at the bottom of the reservoir tank and pull the reservoir from the body. Remove the cap and strainer.
- Remove the two rubber grommets from the housing.
- Clamp the master cylinder body in a vise.
- Push the pistons all the way in with a screwdriver and remove the piston stopper bolt and gasket.
- Keep the piston depressed and remove the snapring using snapring pliers.
- Place a shop towel on two blocks of wood and lightly tap the flange of the body against the blocks until the tip of the piston is visible.
- Pull the pistons with springs by hand straight out of the bore. If the piston(s) is cocked during removal, damage to the piston bore may result.
- After washing all parts in clean brake fluid, dry them with compressed air (if available). Inspect the cylinder bore for wear, scuff marks, or nicks. It may be cleaned, but in view of the importance of the master cylinder, it is recommended that it is replaced rather than overhauled if worn or damaged.
- Absolute cleanliness is important. Coat all parts with clean brake fluid prior to assembly. Coat the lips of all the rubber grommets and pistons with lithium soap based glycol grease prior to installation.
- Insert the two springs and pistons straight into the bore being careful not to damage the rubber lips of the piston.
- Depress the pistons all the way in with a screwdriver and install the snapring.
- Keep the piston depressed and install the piston stopper bolt over the gasket. Torque the bolt to 7 ft. lbs.
- Push the two rubber grommets into the openings in the master cylinder body.
- Install the cap and strainer and push the reservoir onto the cylinder. Keep hand pressure on the reservoir and install the set screw. Torque the set screw to 15.2 inch lbs.
Because the seal between the reservoir and the master cylinder is made by rubber grommets, the set screw is designed not to separate the reservoir from the cylinder and will not tighten down the reservoir. Due to the nature of this type of seal, there will be a clearance between the head of the screw and the body. This clearance is normal and no attempt should be made to shim it up with washers or a spacer.
- Install the master cylinder onto the vehicle.
- Fill the brake fluid reservoir to the proper level with clean brake fluid and bleed the master cylinder as described in this section.
- Check for leaks. Check and/or adjust the brake pedal as required.