Brake Master Cylinder: Service and Repair
Master Cylinder ReplacementNOTICE
^ 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.
^ Be careful not to damage or deform the brake lines during removal and installation.
^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent.
1. Release the engine wire harness clips on the strut brace (A), and remove the strut brace. With M/T: Remove the clutch reservoir bracket from the vehicle, and move it aside. Do not disconnect the clutch hose from the reservoir.
2. Remove the reservoir cap and brake fluid from the master cylinder reservoir.
3. Remove the brake fluid level sensor connector (A).
4. Disconnect the brake lines (B) from the master cylinder (C). To prevent spills, cover the hose joints with rags or shop towels.
5. Remove the master cylinder mounting nuts (D) and washers.
6. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder.
7. Remove the rod seal (F) from the master cylinder.
8. Install the master cylinder in the reverse order of removal, and note these items:
^ Replace all the rubber parts with new ones whenever the master cylinder is removed.
^ Check the pushrod clearance before installing the master cylinder, and adjust it if necessary.
^ Use a new rod seal on reassembly.
^ Coat the inner bore lip and outer circumference of the new rod seal with the Shin-Etsu silicone grease (P/N 08798-9013).
^ Install the rod seal onto the master cylinder with its grooved side (G) toward the master cylinder.
^ Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary.
^ Bleed the brake system.
9. Spin the wheels to check for brake drag.