Master Cylinder

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.

1. Disconnect the negative battery cable from the battery.
2. If equipped, disconnect the level warning switch connector from the master cylinder.

   Fig. 1: View of the master cylinder mounting on the brake booster

   Fig. 2: Disconnect the level warning harness from the brake master cylinder

3. A small screen is located inside the reservoir, remove it.
4. Using a syringe, remove the brake fluid from the master cylinder.

   Fig. 3: Siphon out the old brake fluid from the reservoir

5. Using a line wrench, disconnect the brake lines from the master cylinder.

   Fig. 4: Only use a brake line wrench to disconnect the metal tubes

   Fig. 5: Unscrew and carefully remove the brake line from the cylinder

6. Remove the master cylinder-to-power booster mounting nuts.
7. A bracket is behind one of the retaining nuts, remove this and set aside.

   Fig. 6: The upper left retaining nut has a bracket behind it

8. Remove the master cylinder assembly and gasket from the power brake unit.

   Fig. 7: Place a rag under the cylinder to catch any spilt fluid from the cylinder during removal

   Fig. 8: Extract the master cylinder from the four studs from the brake booster

9. It is recommended to discard the old gasket if the unit has never been removed.

   Fig. 9: Remove and discard the old gasket

   To install:

10. Adjust the length of the brake booster pushrod as follows:
    1. Install a new gasket on the master cylinder.
    2. Install SST 09737–00010, or equivalent, on the master cylinder gasket and lower the pin until its tip slightly touches the piston.
    3. Turn the tool upside down and position it on the brake booster.
    4. Measure the clearance between the booster pushrod and the pin head on the SST tool.
    5. There should not be any clearance. If not, adjust the booster pushrod length until the pushrod lightly touches the pin head.

       NOTE: When adjusting the pushrod, depress the brake pedal so that the pushrod sticks out.

11. Remove the SST tool and install the master cylinder to the brake booster using a new gasket.
12. Install the master cylinder four nuts and torque the nuts to 9 ft. lbs. (13 Nm).
13. Using a line wrench, connect the two brake lines to the master cylinder. Torque the union nuts to 11 ft. lbs. (15 Nm).
14. Connect the level warning switch connector.
15. Place the screen into the reservoir.
16. Fill the brake reservoir with brake fluid and bleed the brake system.
17. Check and adjust brake pedal.
18. Connect the negative battery cable to the battery.