Toyota Cressida/Corona/Crown/MarkII 1970-1982 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION





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Fig. Fig. 1 Using a brake line wrench, disconnect the hydraulic lines from the master cylinder



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Fig. Fig. 2 Remove the mounting nuts to separate the cylinder from the booster



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Fig. Fig. 3 Disconnect the ESP sensor (brake fluid warning level sensor) if equipped



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Fig. Fig. 4 Siphon as much fluid out of the master cylinder as possible



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Fig. Fig. 5 Use a line wrench to separate the brake tube from the master cylinder



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Fig. Fig. 6 Remove the mounting nuts retaining the master cylinder to the brake booster



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Fig. Fig. 7 Hold the cylinder upright so as not to spill any fluid



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Fig. Fig. 8 Once the master cylinder is installed, be sure to thread in and tighten the line fittings



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Fig. Fig. 9 If so equipped, attach the ESP wiring and install the cap


WARNING
Be careful not to spill brake fluid on the painted surfaces of the vehicle. It will damage the paint.

  1. Using a siphon, remove as much fluid from the master cylinder as possible, then reinstall the cap.
  2.  
  3. Unfasten the hydraulic lines from the master cylinder.
  4.  
  5. Detach the hydraulic fluid pressure differential switch wiring connectors. On models with ESP (brake fluid level warning device), disconnect the fluid level sensor wiring connectors, as well.
  6.  
  7. On models with manual brakes and on the Crown 2300, remove the master cylinder securing bolts and the clevis pin from the brake pedal. Remove the master cylinder.
  8.  
  9. On the other models with power brakes, unfasten the nuts and remove the master cylinder assembly from the power brake unit.
  10.  
  11. Installation is performed in the reverse order of removal. Note the following, however:
  12.  
    1. Before tightening the master cylinder mounting nuts or bolts, screw the hydraulic line into the cylinder body, a few turns.
    2.  
    3. After installation is completed, bleed the master cylinder and the brake system.
    4.  


OVERHAUL





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Fig. Fig. 10 Exploded view of the typical tandem brake master cylinder assembly



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Fig. Fig. 11 With the cylinder in a vise, separate the reservoir from the unit



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Fig. Fig. 12 Push the pistons in all the way and remove the stopper bolt



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Fig. Fig. 13 Use a pair of snapring pliers to remove the snapring



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Fig. Fig. 14 Apply lithium grease to the rubber parts of the piston



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Fig. Fig. 15 When installing, confirm that the UP mark of the boot is in the correct position



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Fig. Fig. 16 Adjust the length of the booster pushrod before installing the master cylinder



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Fig. Fig. 17 Fill the reservoir and bleed the system of air BEFORE driving

  1. Remove the reservoir caps and floats. Unscrew the bolts and secure the reservoirs to the main body.
  2.  
  3. Remove the pressure differential warning switch assembly (if equipped). Then, working from the rear of the cylinder, remove the boot, snapping, stop washer, piston No. 1, spacer, cylinder cup, spring retainer, and spring, in that order.
  4.  

Depending on the model, it may be necessary to remove the side mounted stop bolt before the pistons can be removed.

  1. Remove the endplug and gasket from the front of the cylinder, then remove the front piston stop-bolt from underneath. Pull out the spring, retainer, piston No. 2, spacer, and the cylinder cup.
  2.  
  3. Remove the two outlet fittings, washers, check valves and springs.
  4.  
  5. Remove the piston cups from their seats only if they are to be replaced.
  6.  
  7. 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. Cylinders may be honed slightly, but the limit is 0.15mm. In view of the importance of the master cylinder, it is recommended that it is replaced rather than overhauled if worn or damaged.
  8.  
  9. Assembly is performed in the reverse order of disassembly. Absolute cleanliness is important. Coat all parts with clean brake fluid prior to assembly.
  10.  

Bleed the hydraulic system after the master cylinder is installed, as detailed following.

 
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