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Brake Master Cylinder: Removal

CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See THREAD LOCKING DEVICES for information.
CAUTION: Remove brake fluid spillage immediately from paint work, with clean water.
  1. Position vehicle on a four-post lift.
  2. Open engine compartment and fit paint work protection covers to fenders.
  3. Disconnect the battery ground lead. Refer to BATTERY GROUND CABLE .
  4. Remove engine compartment rear cover. Refer to ENGINE COVER .
  5. Remove pedal housing, brake booster and master cylinder assembly. Refer to BRAKE PEDAL AND BRACKET, BRAKE BOOSTER AND BRAKE MASTER CYLINDER  .
  6. Place assembly on a work bench.
  7. Remove nuts securing master cylinder to brake booster.
    Fig 1: Removing Nuts Securing Master Cylinder To Brake Booster
    G03116153
  8. Remove master cylinder from brake booster.
    • Remove master cylinder.
    • Remove and discard seal.
    Fig 2: Removing Master Cylinder From Brake Booster
    G03116154
  9. Remove filler cap and empty residual brake fluid into a container. Fit cap.
  10. Remove fluid reservoir from master cylinder.
    • Remove locating pin.
    • Pull reservoir from master cylinder.
    Fig 3: Removing Fluid Reservoir From Master Cylinder
    G03116155
  11. Install plugs into fluid reservoir ports.
    Fig 4: Installing Plugs Into Fluid Reservoir Ports
    G03116156
  12. Remove and discard seals from master cylinder.
    Fig 5: Removing Seals From Master Cylinder
    G03116157
  13. Install plugs into master cylinder ports.
    Fig 6: Installing Plugs Into Master Cylinder Ports
    G03116158
  14. Clean components and mating surfaces.