Master Cylinder Replacement JD9, JF3, JF7

Master Cylinder Replacement Two-Mode Hybrid

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes.

1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.

Note: During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process.

2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
3. Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container.
4. Disconnect the brake fluid level sensor electrical connector.



5. Disconnect the brake master cylinder reservoir return hose quick connect (1) and position the hose aside.
6. Disconnect the brake master cylinder reservoir supply hose quick connect (2) and position the hose aside.



7. Disconnect the brake master cylinder primary brake pipe fitting (1).

Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




8. Disconnect the brake master cylinder left supply brake pipe fitting (1).

Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




9. Disconnect the brake master cylinder right supply brake pipe fitting (1).

Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




10. Disconnect the brake master cylinder right front brake pipe fitting (1).

Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




11. Disconnect the brake master cylinder left front brake pipe fitting (1).

Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




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

Discard the brake master cylinder nuts.




13. Remove the brake master cylinder and the master cylinder seal (1).

1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding.



2. Install the brake master cylinder seal (1) and the master cylinder to the adapter.

Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing.

Caution: Refer to Fastener Caution in the Preface section.




3. Install 2 new brake master cylinder nuts (1).

Tighten
Tighten the nuts to 33 N·m (24 lb ft).




4. Connect the brake master cylinder left front brake pipe fitting (1).

Tighten
Tighten the fitting to 30 N·m (22 lb ft).




5. Connect the brake master cylinder right front brake pipe fitting (1).

Tighten
Tighten the fitting to 30 N·m (22 lb ft).




6. Connect the brake master cylinder right supply brake pipe fitting (1).

Tighten
Tighten the fitting to 30 N·m (22 lb ft).




7. Connect the brake master cylinder left supply brake pipe fitting (1).

Tighten
Tighten the fitting to 30 N·m (22 lb ft).




8. Connect the brake master cylinder primary brake pipe fitting (1).

Tighten
Tighten the fitting to 30 N·m (22 lb ft).




9. Connect the brake master cylinder reservoir return hose quick connect (1).
10. Connect the brake master cylinder reservoir supply hose quick connect (2).
11. Connect the brake fluid level sensor electrical connector.
12. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling.
13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.

Master Cylinder Replacement JH6, JH7