Page D-3
Repair and Service Manual
B
B
BRAKES
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Do not allow brake fluid to contact surfaces. Wipe off
immediately.
After making any repairs to hydraulic lines, wheel cylin-
ders or master cylinder, the brakes must be bled to
remove any trapped air. A bleeder valve is located at
each wheel cylinder for this purpose. See ‘BLEEDING
AND FLUSHING’ on page D-9.
MASTER CYLINDER
Just like any other brake part, the master cylinder will
eventually require replacement. The usual reason for a
master cylinder failure is the cylinder seals (cups) deteri-
orate. Fluid leaks past the cups and shows as an exter-
nal leak. A common symptom is a ‘spongy’ brake pedal
that goes all the way to the floor when all the other brake
components are in good condition. The rubber parts
wear with usage or deteriorate with age or fluid contami-
nation. Corrosion or deposits formed in the cylinder bore
due to moisture or dirt in the hydraulic system may result
in wear of the cylinder bore or related parts. Do not try to
remove corrosion or deposits with a cylinder hone. If
corrosion or deposits are present, discard master cylin-
der and replace with new one.
Brake Fluid
Hydraulic brake systems must be totally flushed if the fluid
becomes contaminated with water, dirt or other corrosive
chemicals. To flush, bleed the entire system until all brake fluid
has been replaced with fresh DOT 3 standard automotive
brake fluid
.
It is important to maintain proper fluid levels in the mas-
ter cylinder. The fill cap for the cylinder is located under
the driver seat. To prevent contamination when checking
fluid, wipe off any dirt from fill cap before removing it.
Reservoir fluid level should be checked per ‘PERIODIC
SERVICE SCHEDULE’ in Section A. When required,
clean brake fluid should be added to maintain fluid level
1/4” (6 mm) from top of reservoir. Use fresh DOT 3 stan-
dard automotive brake fluid.
Master Cylinder Replacement
Tool List
Qty.
Insulated wrench ......................................................... 1
Shop towels............................................................. A/R
Catch pan .................................................................... 1
Wrench, 3/8”................................................................ 1
Wrench, 5/8” ................................................................1
Needle nose pliers .......................................................1
Wrench, 9/16” ..............................................................2
Wrench, 1" ...................................................................1
Wrench, 7/16” ..............................................................1
Teflon tape ...............................................................A/R
Crowsfoot, 1" ...............................................................1
Torque wrench, in. lbs..................................................1
Socket, 7/16”................................................................1
Crowsfoot, 5/8” ............................................................1
Socket, 9/16”................................................................1
Ratchet ........................................................................1
Wrap wrenches with vinyl tape to prevent the
possibility of a dropped wrench ‘shorting out’
a battery, which could result in an explosion
and severe personal injury or death.
During this process, it is likely
that brake fluid will leak
from the master cylinder. Avoid allowing brake fluid to
contact the painted body components of the vehicle.
Wipe off immediately.
Turn vehicle key to ‘OFF’ and remove. Insure all optional
electrical accessories are turned OFF. At the battery,
remove the negative (-) cables. Cover top of battery with
a cloth or non-conductive material to prevent the possi-
bility of a dropped wrench or metal object from ‘shorting
out’ the battery.
Clean the area around the master cylinder to prevent
dirt and grease from contaminating the hydraulic sys-
tem.
Disconnect wire terminal block from brake light switch
on top of branch tee (Ref Fig. 2 on page D-4).
NOTICE
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