Master Cylinder Replacement

Master Cylinder Replacement

Caution: Refer to Brake Fluid Irritant Caution.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice.

Removal Procedure

1. Apply the park brake and block the wheels.




2. Disconnect the electrical connector from the brake fluid level sensor, if applicable.
3. Remove the driver side upper fender support.

Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination.

4. Disconnect the brake pipes from the master cylinder.
5. Plug the open brake pipe ends.




6. For vehicles with JL4, crimp the hose (4) at the master cylinder to prevent fluid from leaking out.
7. Remove the clamp (5) and hose (4) from the reservoir. Plug the port in the reservoir.




8. Remove the master cylinder mounting nuts.
9. Remove the master cylinder from the vehicle.
10. Remove the master cylinder reservoir.

Installation Procedure

1. Install the master cylinder reservoir.
2. Bench bleed the master cylinder.




3. Install the master cylinder to the vehicle.

Notice: Refer to Fastener Notice.

4. Install the master cylinder mounting nuts.

Tighten the nuts to 36 N.m (27 lb ft).




5. For vehicles with JL4, remove the plug from the reservoir port and install the hose (4) and clamp (5) to the reservoir.
6. Remove the crimping tool from the hose (4).




7.
Remove the rubber cap or plug from the exposed brake pipe fitting ends.
8. Connect the brake pipes.

Tighten the pipe fittings to 25 N.m (18 lb ft).

9. Connect the electrical connector to the brake fluid level sensor.
10. Install the driver side upper fender support.
11. Bleed the hydraulic brake system.
12. Release the park brake and unblock the wheels.