Master Cylinder Replacement Hydraulic Booster C3500HD

1. Apply the parking brake.
2. Disconnect the brake pipes.
3. Plug the pipes in order to prevent brake fluid loss or contamination.



4. Remove the master cylinder nuts.



5. Remove the master cylinder (1) and bracket (2).
6. Remove the retainer (3).

Before you install the master cylinder, bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding .

1. Install the retainer (3).



2. Install the bracket (2) and master cylinder (1).




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the master cylinder nuts.

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

4. Connect the brake pipes.

Tighten
Tighten the pipe fittings to 27 N·m (20 lb ft).

5. Bleed the brakes. Refer to Hydraulic Brake System Bleeding .

Master Cylinder Replacement Hydraulic Booster All Except C3500HD

1. Apply the parking brake.
2. Disconnect the brake pipes.
3. Plug the pipes in order to prevent brake fluid loss or contamination.



4. Remove the master cylinder nuts.



5. Remove the bracket (1) and the master cylinder (2).

Before you install the master cylinder, bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding .

1. Install the master cylinder (2) and bracket (1).




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the master cylinder nuts.

Tighten
Tighten the nuts to 27 N·m (20 lb ft).

3. Connect the brake pipes.

Tighten
Tighten the pipe fittings to 24 N·m (18 lb ft).

4. Bleed the brakes. Refer to Hydraulic Brake System Bleeding .
5. Release the parking brake.

Master Cylinder Replacement Vacuum Booster

1. Apply the parking brake.
2. Disconnect the brake pipes.
3. Plug the pipes in order to prevent brake fluid loss or contamination.



4. Remove the master cylinder nuts.
5. Remove the bracket and the master cylinder.

Before you install the master cylinder, bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding .

1. Install the master cylinder and bracket.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the master cylinder nuts.

Tighten
Tighten the nuts to 27 N·m (20 lb ft).

3. Connect the brake pipes.

Tighten
Tighten the pipe fittings to 24 N·m (18 lb ft).

4. Bleed the brakes. Refer to Hydraulic Brake System Bleeding .
5. Release the parking brake.