Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Master Cylinder

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3


WARNING
Be careful not to spill brake fluid on the painted surfaces. It will damage the paint. If a spill occurs, flush the area with plenty of fresh water.

  1. Bleed the air from the master cylinder.
  2.  
  3. Unplug the fluid level warning switch connector.
  4.  
  5. Use a syringe or similar tool to remove as much fluid as possible from the reservoir.
  6.  
  7. Carefully disconnect the brake lines at the master cylinder. To prevent line damage, use a line wrench. Regular open-end wrenches are NOT recommended. Take great care not to bend or deform the lines. Plug the lines to keep dirt from entering.
  8.  
  9. Remove the nuts holding the master cylinder to the booster. Unbolt the 3-way or 4-way union. When removing the cylinder, take care to recover the clamps, gaskets, etc.
  10.  

To install:
  1. Using a new gasket, install the master cylinder onto the brake booster. Tighten the mounting nuts to 9 ft. lbs. (13 Nm).
  2.  
  3. Attach the union. Carefully connect the brake tubes, initially threading them into place by hand. Once properly engaged, tighten the fittings to 11 ft. lbs. (15 Nm).
  4.  
  5. Connect the wiring harness for the brake fluid switch.
  6.  
  7. Fill the brake fluid reservoir with fluid to the MAX line. Check the leakage.
  8.  
  9. Bleed the brake system. Check again for any leakage.
  10.  
  11. Check and adjust the brake pedal.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of a common brake master cylinder mounting found on Toyotas



Click image to see an enlarged view

Fig. Fig. 2: Using a line wrench, loosen the brake fittings on the cylinder



Click image to see an enlarged view

Fig. Fig. 3: Remove the mounting nuts retaining the master cylinder to the brake booster

 
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