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BRAKE MASTER CYLINDER(for LHD) DISASSEMBLY

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PROCEDURE


  1. Click here

    REMOVE RESERVOIR BRACKET


    1. B004WOL

      Disconnect the connector.

    2. Detach the connector clamp.

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

    4. B004RLD

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

  2. Click here

    REMOVE NO. 2 BRAKE ACTUATOR TUBE


    1. B004UD5

      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. Click here

    REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. B004TQ6

      Detach the clip from the master cylinder bracket.

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

    3. B004WS3

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

    4. B004SCW

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

    5. B004TLK

      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. Click here

    REMOVE TUBE CLAMP BRACKET


    1. B004YTN

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

  5. Click here

    REMOVE NO. 1 BRAKE ACTUATOR BRACKET


    1. B004S6T

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

  6. Click here

    REMOVE BRAKE STROKE SIMULATOR CYLINDER SUB-ASSEMBLY


    1. B004WFU

      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. Click here

    REMOVE BRAKE MASTER CYLINDER TUBE


    1. B004WLY

      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. Click here

    REMOVE NO. 1 BRAKE ACTUATOR TUBE


    1. B004T62

      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. Click here

    REMOVE BRAKE STROKE SIMULATOR BRACKET


    1. B004W0L

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

  10. Click here

    REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. B004VIQ

      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. Click here

    REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY

  12. Click here

    REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER

  13. Click here

    INSTALL MASTER CYLINDER RESERVOIR GROMMET


    1. B004RTA

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

  14. Click here

    REMOVE MASTER CYLINDER PUSH ROD CLEVIS


    1. B004TJM

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

      Tip:

      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.