REMOVAL & INSTALLATION

See Figures 1 through 7

The brake master cylinder is located in the engine compartment and usually attached to a brake booster on the driver's side of the vehicle.

Before the master cylinder is reinstalled, the brake booster pushrod must be adjusted. This adjustment requires the use of factory special tool SST No. 09737-00010 or its equivalent.



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Fig. Fig. 1: Exploded view of the brake master cylinder

  1. Open the hood and disconnect the level warning switch wiring.
    2.  



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Fig. Fig. 2: Disconnect the level sensor wiring from the cap, then remove the cap

  1. Disconnect the negative battery cable.
    2.  
  2. Remove the cap from the master cylinder and drain the fluid out with a syringe. Deposit the fluid into a container.
    3.  


WARNING
Do not allow the fluid to touch the painted surface of your vehicle, if so wash off the fluid immediately.

  1. Disconnect the brake tubes from the master cylinder. Drain the fluid from the lines into the container. Plug the lines to prevent fluid from leaking onto and damaging painted surfaces or the entry of moisture into the brake system.
    2.  



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Fig. Fig. 3: Always use line wrenches to disconnect all brake tubing



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Fig. Fig. 4: Carefully, without bending the line move it to the side of the cylinder

  1. Remove the three nuts that attach the master cylinder and 3-way union to the brake booster.
    2.  



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Fig. Fig. 5: Using an extension, loosen and remove the cylinder retaining bolts



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Fig. Fig. 6: Carefully move aside the union to allow enough room to pull the master cylinder from the brake booster

  1. Remove the master cylinder from the booster studs. Remove and discard the old gasket. The 2-way (w/ABS) or 3-way (wo/ABS) should come off with the cylinder.
    2.  



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Fig. Fig. 7: Discard the old gasket and install a new one prior to installation

To install:
  1. Clean the brake booster gasket and the master cylinder flange surfaces. Install a new gasket for the master cylinder onto the brake booster.
    2.  
  2. Adjust the length of the brake booster push rod as follows:
    1. Set the special tool on the master cylinder with the gasket and lower the pin of the tool until it lightly contacts the piston.
      2.  
    2. Turn the special tool upside-down and position it onto the booster.
      3.  
    3. Measure the clearance between the booster push rod and the pin head of the tool. There must be zero clearance. To obtain zero clearance, adjust the push rod length until the push rod just contacts the head of the pin.
      4.  

    3.  
  3. Before installing the master cylinder, make sure that the UP mark is in the correct position. Install the master cylinder over the mounting studs and tighten the three nuts to 9 ft. lbs. (13 Nm).
    4.  
  4. Connect the tubes to the master cylinder outlet plugs and tighten the union nuts to 11 ft. lbs. (15 Nm).
    5.  
  5. Connect the level warning switch wiring.
    6.  
  6. Fill the brake fluid reservoir to the proper level with clean brake fluid and bleed the brake system as described in this Section.
    7.  


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. Check for leaks. Check and/or adjust the brake pedal.
    2.