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

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

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

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



2. Remove the rear and left front brake pipes from the brake master cylinder.

Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.




3. Remove the right front brake pipe 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 electrical connector for the fluid level sensor.
6. Remove the knee bolster. Refer to Driver Knee Bolster Replacement .
7. Remove the knee bolster bracket. Refer to Driver Knee Bolster Bracket Replacement .



8. Remove the retainer from the clevis pin.
9. Remove the clevis pin from the master cylinder push rod and the brake pedal.




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

10. Remove the nuts for the brake master cylinder (2).
11. Remove the brake master cylinder and power brake booster assembly (1).

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

Notice: Refer to Fastener Notice in the Preface section.

2. Install the master cylinder nuts (2).

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




3. Install the clevis pin to the master cylinder push rod and the brake pedal.
4. Install the retainer to the clevis pin.
5. Install the knee bolster bracket. Refer to Driver Knee Bolster Bracket Replacement .
6. Install the knee bolster. Refer to Driver Knee Bolster Replacement .
7. Connect the electrical connector for the brake fluid level sensor.
8. Connect the electrical connectors at the BPMV.



9. Install the right front brake pipe fitting to the master cylinder.

Tighten
Tighten the fittings to 19 N·m (14 lb ft).




10. Install the rear and left front brake pipe fittings to the brake master cylinder.

Tighten
Tighten the fittings to 19 N·m (14 lb ft).

11. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment .
12. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .

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

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

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

1. Apply and release the brake pedal at least 20 times to release the power brake accumulator reserve pressure.
2. Mark the location of the brake pipes to the master cylinder.



3. Disconnect the 4 brake pipe fittings from the master cylinder.

Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.




4. Disconnect the brake fluid level sensor (1) electrical connector.
5. Disconnect the electrical connectors (2) and (3) at the brake pressure modulator valve (BPMV) and module assembly.
6. Remove the driver knee bolster bracket. Refer to Driver Knee Bolster Bracket Replacement .



7. Remove the retainer (1) from the clevis pin.
8. Remove the clevis pin (2) from the master cylinder pushrod and the brake pedal.



9. Remove the 4 master cylinder nuts (1).

Reposition any wiring harnesses as necessary to improve access to the master cylinder nuts.




10. Remove the master cylinder with power brake booster assembly.

1. Install the master cylinder with power brake booster assembly.

Notice: Refer to Fastener Notice in the Preface section.




2. Install the 4 master cylinder nuts (1).

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

3. Position any wiring harnesses which were moved to access the master cylinder nuts to the retainers.



4. Install the clevis pin (2) to the master cylinder pushrod and the brake pedal.
5. Install the retainer (1) to the clevis pin.
6. Verify the correct installation of the retainer by rotating the retainer 360 degrees.

The retainer must rotate freely and not become disengaged from the groove in the clevis pin.

7. Install the driver knee bolster bracket. Refer to Driver Knee Bolster Bracket Replacement .



8. Connect the brake fluid level sensor (1) electrical connector.
9. Connect the electrical connectors (2) and (3) at the BPMV and module assembly.



10. Connect the 4 brake pipe fittings to the master cylinder.

Tighten
Tighten the fittings to 19 N·m (14 lb ft).

11. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment .
12. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment .
13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .