Replacement

CAUTION: Do not allow brake fluid to get on painted surfaces.

NOTE: Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rubber components may result. If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque values specified are for dry, unlubricated fasteners.





REMOVAL
1. Clean around reservoir cap and take out fluid with syringe or equivalent.
2. Remove P & Differential valve.
3. Disconnect reservoir lead wire at coupler.
4. Disconnect brake pipes from master cylinder.
5. Remove attaching nuts/washers.





6. Loosen brake booster attaching nuts to such extent as to allow brake booster to move





7. Move brake booster and master cylinder together as shown in figure and remove master cylinder only.

INSTALLATION

NOTE: Adjust clearance between booster piston rod and primary piston with special tool.





1. After moving brake booster a little as shown in figure, install master cylinder to brake booster.





2. Torque booster attaching nuts to (a): 13 Nm (9.5 ft. lbs.)





3. Torque master cylinder attaching nuts to (b): 13 Nm (9.5 ft. lbs.)
4. Connect hydraulic lines and torque flare nuts to (c): 16 Nm (12.0 ft. lbs.)
5. Connect reservoir lead wire.
6. Fill reservoir with specified brake fluid.
7. After installing, check brake pedal play and bleed air from system.
8. Perform brake test and check each installed part for fluid leakage.