Recall - Potential Brake Master Cylinder Leaks: Overview
10-047FEBRUARY 25, 2011
Applies To:
2005 RL - From VIN JH4KB16..5C000001 thru JH4KB16..5C021598
2006 RL - From VIN JH4KB16..6C000002 thru JH4KB16..6C012556
2007 RL - From VIN JH4KB16..70000202 thru JH4KB16..7C003061
Safety Recall: Master Cylinder May Be Leaking
(Supercedes 10-047, dated November 6, 2010, to revise the information marked by black bars/shown with asterisks.
REVISION SUMMARY
BACKGROUND
A cup seal in the master cylinder is sensitive to the type of brake fluid used in the brake system. If the brake fluid is replaced with anything other than Acura (or Honda) Genuine DOT 3 Brake Fluid, and the brakes are manually bled, the cup seal may twist in its retention groove and create a small leak. The brake fluid can then leak into the brake booster, and the brake system indicator will eventually come on because the brake fluid level is low.
If the client continues to drive the vehicle without refilling the brake fluid reservoir, they may notice the brake pedal feels low or spongy. The client should not rely on refilling the brake fluid reservoir to address the problem. A prolonged leak would eventually cause one of the two brake system hydraulic circuits to fail.
CLIENT NOTIFICATION
Owners of affected vehicles will receive a notification of this campaign. An example of the client notification letter is shown in this service bulletin.
Not all vehicles in the Applies To ranges are affected by this campaign. To verify vehicle eligibility, you must check at least one of these items:
^ The client has a notification letter.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition, check for a punch mark above the ninth character of the engine compartment VIN. A punch mark in that location means this campaign has already been completed.
Some vehicles affected by this campaign may be in your used vehicle inventory. As a matter of federal law, these vehicles must be repaired before they are sold.
Should a dealership sell an unrepaired vehicle that subsequently causes an injury or damage because of the recalled item, the dealership will be solely responsible to the damaged party, and will be required to defend and indemnify American Honda for any resulting claims. To see if a vehicle in inventory is affected by this campaign, do a VIN status inquiry before selling it.
CORRECTIVE ACTION
Install a master cylinder repair kit and, if needed, replace the brake booster.
PARTS INFORMATION
REQUIRED MATERIALS
WARRANTY INFORMATION
REPAIR PROCEDURE
NOTE:
This procedure is in an outline form that you can also use as a checklist for the repair. If you need more details on the procedures listed below, bookmark them in the appropriate service manual, or view them online:
^ Under-hood Fuse/Relay Box Removal and Installation
^ Frame Brace Replacement
^ Master Cylinder Replacement
^ Brake Booster Replacement
^ Brake System Bleeding
^ Brake Pedal and Brake Pedal Position Switch Adjustment
1. Remove the engine covers.
2. Remove the under-hood fuse/relay box, and move it aside.
3. Remove the strut brace.
4.* Deplete the vacuum in the brake booster by pumping the brake pedal at least five times.*
5. Remove the brake fluid from the master cylinder reservoir with a syringe.
6. Remove the master cylinder. Be careful not to bend or damage the brake lines.
7. Check for brake fluid leaking from the installed end of the master cylinder:
^ If there is a leak, go to step 8.
^ If there is no leak, go to step 9.
8. Replace the brake booster. Replacement includes checking the adjustment of the brake pedal height and the brake pedal position switch. Torque the brake booster mounting nuts to 13 Nm (9.4 lb-ft).
NOTE:
^ * Do not overtighten the mounting nuts.
^ Be careful not to bend or damage the brake lines.*
9. Place the master cylinder on clean shop towel on your work bench, then pull out the piston from the end of the master cylinder. A small amount of brake fluid will come out behind the piston; this is normal.
10. Remove the cup seal from the end of the master cylinder using the seal extractor (wire tie).
NOTE:
To avoid damaging the cup seal retention groove in the master cylinder, do not use a seal pick or any other metal tool to remove the cup seal.
11. Coat the new cup seal with the grease supplied in the kit.
12. Install the new cup seal, by hand, into the seal groove at the end of the master cylinder. Install the seal with its cupped side facing the master cylinder.
13. * Coat the piston with a thin layer of the grease supplied in the kit, then reinstall the piston into the master cylinder.
NOTE
* Make sure you insert the end of the piston with the holes into the master cylinder.*
14. Reinstall the master cylinder.
^ Use a new 0-ring coated with clean brake fluid.
^ Torque the mounting nuts to 13 Nm (9.4 lb-ft).
*NOTE:
Do not overtighten the mounting nuts.*
^ Torque the brake line nuts to 22 Nm (16 lb-ft).
15. Reinstall the strut brace, the under-hood fuse/relay box, and the engine covers.
16. Bleed the brake system.
17. Center-punch a completion mark above the ninth character of the engine compartment VIN:
