BRAKE MASTER CYLINDER(for LHD) DISASSEMBLY

PROCEDURE


  1. REMOVE RESERVOIR BRACKET


    1. B004BDK

      Disconnect the connector.

    2. Detach the connector clamp.

    3. Detach the 2 claws and disconnect the wire harness.

    4. B004BW5

      Remove the bolt and reservoir bracket from the brake master with stroke simulator cylinder assembly.

  2. REMOVE NO. 2 BRAKE ACTUATOR TUBE


    1. B000S88

      Using a union nut wrench, disconnect the No. 2 brake actuator tube.

    2. Remove the bolt and No. 2 brake actuator tube.

      Note


      • Do not kink or damage the No. 2 brake actuator tube.

      • Do not allow any foreign matter such as dirt or dust to enter the No. 2 brake actuator tube from the connecting parts.

  3. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. B004BYZ

      Detach the clip from the master cylinder bracket.

    2. Remove the bolt and brake actuator case from the master cylinder bracket.

    3. B004AX2

      Slide the clip and disconnect the reservoir hose from the brake master cylinder reservoir assembly and brake booster with accumulator pump assembly.

    4. B004C5F

      Remove the nut and brake booster with accumulator pump assembly from the brake master with stroke simulator cylinder assembly.

    5. B004ARM

      Remove the 2 brake booster pump bushes and 2 brake booster pump collars from the brake booster with accumulator pump assembly.

    6. Remove the brake booster pump bush and brake booster pump collar from the brake stroke simulator bracket.

  4. REMOVE TUBE CLAMP BRACKET


    1. B004AXX

      Remove the bolt and tube clamp bracket from the brake booster with accumulator pump assembly.

  5. REMOVE NO. 1 BRAKE ACTUATOR BRACKET


    1. B004BQ6

      Remove the bolt and No. 1 brake actuator bracket from the brake booster with accumulator pump assembly.

  6. REMOVE BRAKE STROKE SIMULATOR CYLINDER SUB-ASSEMBLY


    1. B000OVB

      Using a union nut wrench, disconnect the brake master cylinder tube from the brake stroke simulator cylinder sub-assembly.

      Note


      • Do not kink or damage the brake master cylinder tube.

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

    2. Remove the 2 bolts and brake stroke simulator cylinder sub-assembly from the brake stroke simulator bracket.

  7. REMOVE BRAKE MASTER CYLINDER TUBE


    1. B000RRP

      Using a union nut wrench, disconnect the brake master cylinder tube from the brake master cylinder sub-assembly.

      Note


      • Do not kink or damage the brake master cylinder tube.

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

  8. REMOVE NO. 1 BRAKE ACTUATOR TUBE


    1. B000OZE

      Using a union nut wrench, disconnect the No. 1 brake actuator tube from the brake master cylinder sub-assembly.

      Note


      • Do not kink or damage the No. 1 brake actuator tube.

      • Do not allow any foreign matter such as dirt or dust to enter the No. 1 brake actuator tube from the connecting parts.

  9. REMOVE BRAKE STROKE SIMULATOR BRACKET


    1. B000SM1

      Remove the 3 bolts and brake stroke simulator bracket from the brake master cylinder sub-assembly.

  10. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. B000OEP

      Mount the brake master cylinder sub-assembly in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the brake master cylinder sub-assembly.

    2. Using a pin punch and hammer, remove the pin from the brake master cylinder reservoir assembly.

    3. Remove the brake master cylinder reservoir assembly from the brake master cylinder body.

  11. REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY

  12. REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER

  13. REMOVE MASTER CYLINDER RESERVOIR GROMMET


    1. B000R3J

      Remove the 2 master cylinder reservoir grommets from the brake master cylinder body.

  14. REMOVE MASTER CYLINDER PUSH ROD CLEVIS


    1. B000ROL

      Loosen the lock nut and remove the master cylinder push rod clevis and lock nut.

      Tech Tips

      Measuring the protrusion of the push rod from the master cylinder push rod clevis in advance makes it easier to adjust the brake pedal height after the brake master cylinder sub-assembly is installed.