Prepare
1. Remove main fuse. See Power disconnect.
2. Remove exhaust system. See Exhaust system.
3. Drain brake fluid from rear brake system. See Bleed brakes.
Remove
1. See Figure 3-30. Disconnect brake line from master cylinder.
- a. Disconnect rear brake lamp switch connectors (6).
- b. Remove rear brake lamp switch (5).
- c. Discard washers (4).
- d. Set brake line (7) aside.
2. Remove rear brake master cylinder.
- a. Remove master cylinder mounting screws (3).
- b. Remove master cylinder (1) from pushrod (2).
Figure 3-30. Rear Brake Master Cylinder: 1. Brake master cylinder assembly; 2. Pushrod; 3. Screw (2); 4. Washer (2); 5. Brake lamp switch; 6. Brake lamp switch connector (2); 7. Brake line
Install
| FASTENER | TORQUE VALUE | |
| Rear brake master cylinder mounting screw | 9.5-10.5 Nm | 84-92 in·lbs |
| Rear brake master cylinder banjo bolt | 17.0-20.0 Nm | 13-14 ft·lbs |
1. See Figure 3-30 Install rear brake master cylinder.
- a. Install master cylinder (1) over pushrod (2)
- b. Align master cylinder to frame.
- c. Install master cylinder mounting screws (3). Tighten to 9.5-10.5 Nm (84-92 in·lbs)
Notice: Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly.
2. Install rear brake line.
- a. Install rear brake lamp switch (5), new washers (4) and brake line (7) to rear brake master cylinder. Tighten to 17.0-20.0 Nm (13-14 ft·lbs).
3. Connect rear brake lamp switch connectors (6).
Clean and inspect
Warning: Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after. Clean all parts thoroughly.
2. Inspect rubber boot for damage. Replace as necessary.
Complete
1. Fill and bleed rear brake system. See Bleed brakes.
2. Install exhaust system. See Exhaust system.
3. Install main fuse. See Power disconnect.er assembly. Deterioration of these components can cause brake failure, which could result in death or serious injury.