LEMON Manuals: Even more car manuals for everyone
Home >> Honda >> 2000 >> Insight >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc Brakes And Drum Brakes >> Adjustments >> Master Cylinder Push Rod

Master Cylinder Push Rod

NOTE: You will need to use the pushrod adjustment gauge. See SPECIAL TOOLS  . The master cylinder pushrod to piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder.
  1. Set the special tool (A) on the master cylinder body (B), push in the center shaft (C) until the top of it contacts the end of the secondary piston (D) by turning the adjusting nut (E). See Fig 1 .
    Fig 1: Identifying Master Cylinder Pushrod Clearance Setup
    G00126394Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Without disturbing the center shaft's position, install the special tool (A) backwards on the booster. See Fig 2 .
    Fig 2: Installing Master Cylinder Special Tool
    G00126395Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Install the master cylinder nuts (B), and tighten to the specified torque. See Fig 2 and TORQUE SPECIFICATIONS  .
  4. Connect the booster in line with the vacuum gauge (C) 0-101 kPa (0-760 mmHg, 30 in. Hg) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mmHg, 20 in. hg) vacuum. See Fig 2 .
  5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B). See If the clearance between the gauge body and the adjusting nut is 0.4 mm (0.02 in.), the pushrod to piston clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is 0 mm, the pushrod to piston clearance is 0.4 mm (0.02 in.) or more. Therefore it must be adjusted and rechecked. See Fig 3 .
    Fig 3: Identifying Gauge Body & Adjusting Nut Clearance
    G00126396Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. If the clearance is incorrect, loosen the star locknut (A) and turn the adjuster (B) in or out to adjust. See Fig 4 .
  7. Adjust the clearance while the specified vacuum is applied to the booster.
  8. Hold the clevis (C) while adjusting. See Fig 4 .
  9. Tighten the star locknut securely.
  10. Remove the special tool (D). See Fig 4 .
    Fig 4: Identifying Clearance Correction
    G00126397Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Check the pushrod length (A), if the booster is removed. If the length is incorrect, loosen the pushrod locknut (B), and turn the clevis (C) in or out to adjust. See Fig 5 .
    Fig 5: Adjusting Pushrod Length
    G00126404Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Install the master cylinder. See MASTER CYLINDER  .
scientia non olet · About LEMON Manuals