Removal and Installation
WARNING:
The traction battery and charging system contains high voltage components and wiring. High voltage insulated safety gloves and a face shield must be worn when carrying out any diagnostics on this vehicle. Failure to follow these instructions may result in severe personal injury or death.
WARNING:
Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNING:
Brake fluid contains polyglycol ethers and poylglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTION:
Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
NOTE:
Brake fluid reservoir shown removed for clarity.
- Disconnect the battery. For additional information refer to BATTERY, MOUNTING AND CABLES .
- Depower the high-voltage battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
- Using a suitable suction device, remove the brake fluid from the master cylinder reservoir.
- Disconnect the brake fluid level switch electrical connector.
- Disconnect the brake travel sensor electrical connector.
- Disconnect and cap the 2 brake line fitting nuts.
- To install, tighten to 14 Nm (10 lb-ft).
- Remove the return hose clamp and the return hose.
- Remove the feed hose clamp and the feed hose.
- Remove the brake pushrod pin redundant clip.
- Remove the brake pushrod self-locking pin.
- Remove the brake pushrod outer bushing.
- Slide the brake pushrod off the brake pedal pin.
- Remove the 4 master cylinder nuts.
- To install, tighten to 23 Nm (17 lb-ft).
- Remove the master cylinder.
- To install, reverse the removal procedure.
- Repower the high-voltage battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
- Bleed the brake system. For additional information, refer to BRAKE SYSTEM-GENERAL INFORMATION .