Master Cylinder Replacement

Master Cylinder Replacement

Removal Procedure
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Vehicle Damage Warnings).

1. Apply and release the brake pedal several times until the pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.
2. Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir.
3. Discard the brake fluid into an approved container.
4. Disconnect the master cylinder fluid level sensor electrical connector.




5. Disconnect the master cylinder secondary brake pipe fitting (1).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
6. Disconnect the master cylinder primary brake pipe fitting (2).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




7. Remove the master cylinder nuts (1).




8. Remove the master cylinder (1).
9. Remove the O-ring seal (2) from the master cylinder body.

Installation Procedure

1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (Master Cylinder Bench Bleeding).




2. Install the master cylinder (1) and the O-ring seal (2) to the power vacuum brake booster.
Ensure the O-ring seal is properly seated in the groove in the master cylinder body.





Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the master cylinder nuts (1) and tighten the nuts to 36 Nm (27 ft. lbs.).




4. Connect the master cylinder secondary brake pipe fitting (1) and tighten the fitting to 32 Nm (24 ft. lbs.).
5. Connect the master cylinder primary brake pipe fitting (2) and tighten the fitting to 32 Nm (24 ft. lbs.).
6. Connect the master cylinder fluid level sensor electrical connector.
7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (Hydraulic Brake System Bleeding (Pressure)).