BRAKE MASTER CYLINDER(for RHD) REASSEMBLY

PROCEDURE


  1. INSTALL MASTER CYLINDER RESERVOIR GROMMET


    1. B005P0PC01
      B005OS0 Lithium Soap Base Glycol Grease

      Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new master cylinder reservoir grommets.

    2. Install the 2 master cylinder reservoir grommets to the brake master cylinder body.

  2. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    1. Secure the brake master cylinder body in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the brake master cylinder body.

    2. Install the brake master cylinder reservoir sub-assembly to the brake master cylinder body.

      Note

      Do not drop the brake master cylinder reservoir sub-assembly.

  3. INSTALL BRAKE MASTER CYLINDER RING PIN


    1. B005O7A

      Using a 5 mm pin punch and a hammer, tap in the brake master cylinder ring pin to secure the brake master cylinder reservoir sub-assembly.

    2. Remove the brake master cylinder sub-assembly from the vise.

  4. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

  5. INSTALL NO. 2 BRAKE TUBE WAY


    1. Install the No. 2 brake tube way to the brake master cylinder sub-assembly.

  6. INSTALL BRAKE MASTER CYLINDER TO WAY TUBE


    1. Temporarily install the brake master cylinder to way tube to the brake master cylinder sub-assembly and No. 2 brake tube way.

      Note


      • Tighten the 2 flare nuts by hand.

      • Do not kink or damage the brake line.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.

    2. B005QB9C01
      *a Bolt
      *b Nut
      *c Washer

      Secure the No. 2 brake tube way to the brake master cylinder sub-assembly with the 2 bolts, 2 nuts and 4 washers as shown in the illustration.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    3. Secure the brake master cylinder sub-assembly with way in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the brake master cylinder sub-assembly and No. 2 brake tube way.

    4. B005L4FC02
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, fully tighten the brake master cylinder to way tube.

      Torque:
      Specified tightening torque
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.45 N*m (178 kgf*cm, 13 ft.*lbf)

    5. Remove the brake master cylinder sub-assembly with way from the vise.

    6. Remove the 2 bolts, 2 nuts and 4 washers.