Recall - Possible Brake Master Cylinder Leakage
10-069April 27, 2011
Applies To:
See VEHICLES AFFECTED
Safety Recall: Master Cylinder May Be Leaking
(Supersedes 10-069, dated February 25, 2011, to revise the information marked by the asterisks)
*REVISION SUMMARY
Under REPAIR PROCEDURE, a note was added about using a high-quality flare nut wrench.*
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 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 customer continues to drive the vehicle without refilling the brake fluid reservoir, he or she may notice the brake pedal feels low or spongy. The customer 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.
VEHICLES AFFECTED
Not all vehicles within the affected VIN ranges are affected by this campaign. To verify vehicle eligibility, you must check at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition, check for a punch mark above the 15th 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.
CUSTOMER NOTIFICATION
Owners of affected vehicles will receive a notification of this campaign. An example of the customer notification is at the end of this service bulletin.
CORRECTIVE ACTION
Install a master cylinder repair kit and, if needed, replace the brake booster.
PARTS INFORMATION
Master Cylinder Repair Kit: P/N 06462-SJA-305
(Includes cup seal, 0-ring, seal extractor [wire tie], and seal grease)
REQUIRED MATERIALS
Honda Genuine DOT 3 Brake Fluid: P/N 08798-9008 (Each repair requires 1-1/2 bottles.)
WARRANTY CLAIM INFORMATION
Failed Part: P/N 46101-SHJ-A03
Defect Code: 5LB00
Symptom Code: R5100
Skill Level: Repair Technician
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:
^ Air Cleaner Removal/Installation
^ Master Cylinder Replacement
^ Brake Booster Replacement
^ Brake System Bleeding
1. Remove the air cleaner and the air duct.
2. Remove the brake fluid from the master cylinder reservoir with a syringe.
3. Remove the master cylinder. Be careful not to bend or damage the brake lines.
NOTE:
To avoid damaging the brake line flare nuts, use a high-quality wrench like Snap-on's crowfoot flare nut wrench (P/N FRHM12) to loosen the nuts.
4. Check for brake fluid leaking from the installed end of the master cylinder:
^ If there is a leak, go to step 5.
^ If there is no leak, go to step 6.
5. 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 N.m (9.4 lb-ft).
NOTE:
^ Do not overtighten the mounting nuts. Doing so can cause the brake booster to make noise, which may lead to a comeback.
^ Be careful not to bend or damage the brake lines.
6. 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.
7. Remove the cup seal from the end of the master cylinder using the seal extractor (wire tie) from the kit.
NOTE:
To avoid damaging the cup seal retention groove in the master cylinder, do not use a pick seal or any other metal tool to remove the cup seal.
8. Coat the new cup seal with the grease supplied in the kit.
9. 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.
10. 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.
11. Reinstall the master cylinder.
^ Use a new 0-ring coated with clean brake fluid.
^ Torque the mounting nuts to 13 N.m (9.4 lb-ft).
NOTE:
Do not overtighten the mounting nuts. Doing so can cause the brake booster to make noise, which may lead to a comeback.
^ Torque the brake line nuts to 22 N.m (16 lb-ft).
12. Reinstall the air duct and the air cleaner.
13. Bleed the brake system.
14. Center-punch a completion mark above the 15th character of the engine compartment VIN: