Page 2233 of 4770
BR0AF±03
W04697
SST
R11405
± BRAKEBRAKE MASTER CYLINDER
BR±11
2034 Author: Date:
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
2. TAKE OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT BRAKE LINES
(a) w/ ABS (& TRAC):
Using SST, disconnect the 4 brake lines.
SST 09023±00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) w/o ABS:
Using SST, disconnect the 5 brake lines.
SST 09023±00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
4. REMOVE MASTER CYLINDER
Remove the 2 nuts, and pull out the 2 or 3±way, master cylinder
and gasket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
Page 2234 of 4770

BR0AG±02
R11406
Soft Jows
R11407
Soft Jows
R12236
A BR±12
± BRAKEBRAKE MASTER CYLINDER
2035 Author: Date:
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (18 kgf´cm, 16 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. Except w/ TRAC:
PLACE CYLINDER IN VISE
4. w/o TRAC:
REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. w/o TRAC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:
If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.
At the time of reassembly, please refer to the follow-
ing item.
Be careful not to damage the rubber lips on the pis-
tons.
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No. 2 piston drops out of the cylinder.
HINT:
Make sure that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).
Page 2235 of 4770
W03570
W03590
± BRAKEBRAKE MASTER CYLINDER
BR±13
2036 Author: Date:
6. w/ TRAC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver, and remove the 2
straight pins by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 pistons and springs by hand, pulling
straight out, not at an angle.
NOTICE:
If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.
At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
HINT:
At the time of reassembly, insert the pistons with elliptic hole
facing vertically.
Page 2236 of 4770
BR0AH±01
BR±14
± BRAKEBRAKE MASTER CYLINDER
2037 Author: Date:
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.
Page 2237 of 4770
BR0AI±02
± BRAKEBRAKE MASTER CYLINDER
BR±15
2038 Author: Date:
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR±12).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows
(See page BR±9).
Page 2238 of 4770
BR0AJ±02
BR±16
± BRAKEBRAKE MASTER CYLINDER
2039 Author: Date:
INSTALLATION
Installation is in the reverse order of removal (See page BR±11).
HINT:
Before installation, adjust length of the brake booster push rod (See page BR±20).
After installation, fill the brake reservoir with brake fluid, bleed the brake system and check for leaks
(See page BR±4).
Check and adjust brake pedal (See page BR±5).
Page 2239 of 4770
BR2237
BR0AK±03
BR2238
1st3rd
2nd
GOOD
NO GOOD
± BRAKEBRAKE BOOSTER ASSEMBLY
BR±17
2040 Author: Date:
BRAKE BOOSTER ASSEMBLY
ON±VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.
Page 2240 of 4770
BR0AL±03
Z19121
Master Cylinder
GasketBrake Booster
Gasket
Pin
Clip
Clevis 2±way
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torquew/ ABS (& TRAC)
3±way
15 (155, 11)
13 (130, 9)
25 (260, 19)
13 (130, 9)
BR±18
± BRAKEBRAKE BOOSTER ASSEMBLY
2041 Author: Date:
COMPONENTS