Brake Master Cylinder: Service and Repair

Master Cylinder/Brake Booster Replacement

NOTE: Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid gets on the paint, wash it off immediately with water.

1. Disconnect the brake fluid level switch connector.

2. Remove the brake fluid from the master cylinder reservoir with a syringe.

3. Disconnect the brake lines from the master cylinder. To prevent spills, cover the line joints with clean rags or shop towels.

4. Remove the master cylinder mounting nuts and washers.

5. Remove the master cylinder from the brake booster. Be careful not to bend or damage the brake lines when removing the master cylinder.

6. Disconnect the brake booster vacuum hose from the brake booster.

7. Remove the lock pin and the clevis pin.

8. Remove the four brake booster mounting nuts.

9. Pull the brake booster forward, and remove the brake booster from the engine compartment. Be careful not to bend or damage the brake lines when removing it.

10. Install the brake booster and master cylinder in the reverse order of removal, and note these items:
- Replace parts with new ones as specified in the illustration.

- Install the rod seal onto the brake booster with its grooved side toward the master cylinder.

- '00-05 models, adjust the pushrod length before installing the booster. Adjustments

- Coat the inner bore lip and outer circumference of the new rod seal with the Shin-Etsu silicone grease (P/N 08798-9013).

- Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

- Check the brake pedal height and free play after installing the master cylinder, and adjust if necessary. Adjustments

- Bleed the brake system. Service and Repair

- Spin the wheels to check for brake drag.