Master Cylinder Reservoir Replacement

Master Cylinder Reservoir Replacement

Removal Procedure

Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).

1. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
Warning: Refer to Brake Fluid Warning (Dangers, Warnings, and Cautions).

Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Caution: Refer to Adding Fluid to the Brake System Caution (Adding Fluid to the Brake System Caution).

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Brake Fluid Effects on Paint and Electrical Components Caution).

2. Apply the park brake and chock the wheels.

Note: With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the vacuum brake booster power reserve.

3. Deplete the vacuum brake booster power reserve.
4. Remove the master cylinder. Refer to Master Cylinder Replacement (Master Cylinder Replacement).




5. Remove the master cylinder reservoir to master cylinder retaining screws (4).

Note: To remove the master cylinder reservoir (2) grasp the master cylinder (3) then pull up on the master cylinder reservoir (2).

6. Remove the master cylinder reservoir (2) from the master cylinder (3).

Note: Master cylinder reservoir seals (1) are single use only components and will not reseal. Install NEW master cylinder reservoir seals (1) whenever the master cylinder reservoir (2) is removed from the master cylinder (3).

7. Remove the two master cylinder reservoir seals (1) from the master cylinder (3).
Discard the 2 master cylinder reservoir seals (1).

Installation Procedure

Warning: Refer to Brake Fluid Warning (Dangers, Warnings, and Cautions).

Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Caution: Refer to Adding Fluid to the Brake System Caution (Adding Fluid to the Brake System Caution).

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Brake Fluid Effects on Paint and Electrical Components Caution).

Note: Lubricate the NEW master cylinder reservoir seals and the outer surface of the NEW master cylinder reservoir to housing barrels with Super DOT 4 or DOT 4 Plus brake fluid from a clean, sealed brake fluid container in order to prevent tearing on installation.

1. Install the NEW master cylinder reservoir seals to the master cylinder body.
Make sure they are fully seated.





Note: Press down on the master cylinder reservoir (2) until the master cylinder reservoir to master cylinder retaining screw holes (3) the master cylinder body (1) are aligned.

2. Install the master cylinder reservoir (2) to the master cylinder body (1).





Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the master cylinder reservoir to master cylinder retaining screws (1) and tighten to 2 Nm (18 lb in).
4. Install the master cylinder. Refer to Master Cylinder Replacement (Master Cylinder Replacement).
5. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).