Master Cylinder & Brake Booster Push Rod Clearance

NOTE: Master cylinder push rod-to-piston clearance must be checked and adjusted before installing master cylinder.

1. Turn Push Rod Adjustment Gauge (07JAG-SD40100) adjustment gauge adjusting bolt until top of it is flush with end of master cylinder piston. Rotate adjuster nut until top of center shaft contacts end of secondary piston. See Fig 1 .
2. Without disturbing adjusting bolt's position, install adjustment gauge upside down on booster. Install master cylinder nuts and tighten to 11 ft. lbs. (15 N.m). Using engine or outside vacuum source, apply a minimum of 20" Hg vacuum to brake booster.
NOTE: If clearance between gauge body and adjusting nut is zero mm, push rod-to-piston clearance is 0.4 mm. If clearance between gauge body and adjusting nut is 0.4 mm, push rod-to-piston clearance is zero mm.
3. Using a feeler gauge, verify clearance between gauge body and adjusting nut is 0-0.016" (0-0.40 mm), 0-0.008" (0-0.20 mm) preferred. See Fig 2 . If clearance is not as specified, loosen star lock nut and turn adjuster in or out to adjust. Hold clevis while adjusting. Tighten star lock nut securely. See Fig 3 . Remove special tool and install a new master cylinder rod seal in the booster.
4. If brake booster is removed, adjust push rod length to 4.55-4.59" (115.5-116.5 mm). After adjustment, loosen clevis end push rod lock nut and turn push rod to obtain correct pedal height. See Fig 4 . See PEDAL PLAY & HEIGHT  . Verify brake lights operate properly. Adjust as necessary. See BRAKE LIGHT SWITCH  .

Fig 1: Setting Push Rod Adjustment Gauge

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 2: Measuring Push Rod Clearance

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 3: Adjusting Push Rod Clearance

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 4: Measuring Booster Push Rod Length

Courtesy of AMERICAN HONDA MOTOR CO., INC.