To remove and install a brake master cylinder, follow these steps. Start by disconnecting the cable from the negative terminal of the battery. Use a syringe or turkey baster to remove fluid from the reservoir. Disconnect the electrical connector for the fluid level sensor. If the vehicle has a manual transmission, disconnect the fluid hose for the clutch master cylinder and plug it in. Prepare rags and caps to cover the fluid fittings and lines once disconnected. Use a flare-nut wrench to loosen the fittings at the ends of the brake lines entering the brake master cylinder, plug the ends, and pull the lines away. Remove the brake master cylinder mounting nuts, pull the brake master cylinder off the studs, and discard the O-ring seal. If installing a new brake master cylinder, transfer the reservoir by removing the roll pin and using a new grommet seal. For installation, measure the clearance between the brake master cylinder and the Brake Booster pushrod if using a new brake master cylinder. Bench bleed the new brake master cylinder by mounting it in a vise and attaching bleeder tubes to the outlet ports. Fill the reservoir with brake fluid, push the pistons into the cylinder to expel air into the reservoir, and repeat until no air bubbles remain. Install a new O-ring seal and mount the brake master cylinder over the studs, tightening the mounting nuts finger tight. Thread the brake line fittings and fully tighten the mounting nuts and fittings to the specified torque. Connect the clutch master cylinder fluid hose if applicable. Fill the reservoir with fluid, bleed the brake master cylinder and brake system, and test the brake operation before resuming normal vehicle use. The remaining installation steps are the reverse of removal. By following these steps, you can effectively remove and install a brake master cylinder.
