Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement

Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement

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


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

1. Apply and release the brake pedal 20 times to deplete the hydraulic brake booster accumulator reserve.

Note: Reference mark the brake pipe location for correct installation.




2. Remove the 2 rear brake pipes (1) from the brake master cylinder.
Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.

Note: Reference mark the brake pipe location for correct installation.




3. Remove the 2 front brake pipes (1) from the brake master cylinder.
Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.
4. Disconnect the electrical connectors at the brake pressure modulator valve (BPMV).
5. Disconnect the brake fluid level sensor electrical connector.




6. Remove the brake master cylinder pushrod retainer bolt (1).




7. Remove the brake master cylinder pushrod retainer (1).




8. Simultaneously remove the brake master cylinder pushrod and the stoplamp switch (1) from the brake pedal clevis pin.

Note: It may be necessary to reposition or remove some of the wiring harnesses from their retainers to provide clearance to remove the brake master cylinder nuts.




9. Remove the brake master cylinder nuts (1).




10. Remove the brake master cylinder and power brake booster assembly (1).

Installation Procedure




1. Install the brake master cylinder and power brake booster assembly (1).

Caution: Refer to Fastener Caution (Fastener Caution).




2. Install the brake master cylinder nuts (1).

Tighten the nuts to 36 Nm (27 lb ft).

3. Position the wiring harnesses to the retainers, if removed.




4. Simultaneously install the brake master cylinder pushrod and the stoplamp switch (1) to the brake pedal clevis pin.




5. Install the brake master cylinder pushrod retainer (1).




6. Install the brake master cylinder pushrod retainer bolt (1).

Tighten the bolt to 10 Nm (89 lb in).




7. Install the 2 front brake pipes (1) to the brake master cylinder.

Tighten the fittings to 25 Nm (18 lb ft).

8. Connect the electrical connectors at the brake pressure modulator valve (BPMV).
9. Connect the brake fluid level sensor electrical connector.




10. Install the 2 rear brake pipes (1) to the brake master cylinder.

Tighten the fittings to 25 Nm (18 lb ft).

11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Pressure) (Hydraulic Brake System Bleeding (Pressure))Hydraulic Brake System Bleeding (Manual) (Hydraulic Brake System Bleeding (Manual)).