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Brake Master Cylinder Replacement

  • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
  • Be careful not to damage or deform the brake lines during removal and installation.
  • Plug the end of a hose and joints to prevent spilling brake fluid.
LHD Model
  1. Remove the dashboard lid (A).
  1. Remove the reservoir cap, and the brake fluid from the reservoir tank with a syringe.

  1. Disconnect the brake fluid level switch connector (A).
  1. Remove the reservoir tank mounting bolt (B) from the bracket (C).

  1. Disconnect the brake lines (A) from the master cylinder (B). To prevent spills, cover the hose joints with rags or shop towels.
  1. Remove the master cylinder mounting nuts (C) and washers (D).
  1. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the bake lines when removing the master cylinder.
  1. Except KG ABS model: Remove the rod seal (F) from the master cylinder.
    NOTE: During installation, set the new rod seal onto the master cylinder with its grooved side (G) toward the master cylinder.
  1. KG ABS model: Remove the O-ring (H) from the master cylinder.
    NOTE: Use the new O-ring during installation.
  1. Install the master cylinder in the reverse order of removal, and note these items:
  1. Spin the wheels to check for brake drag.
KG ABS model:
Except KG ABS model:

RHD Model
  1. Remove the dashboard lid (A).

  1. M/T: Remove the clutch reservoir tank (A), and move it aside. Do not disconnect the clutch line from the reservoir tank.
  1. Remove the reservoir cap and the brake fluid from the reservoir tank with a syringe.

  1. Disconnect the brake fluid level switch connector (A).
  1. Remove the reservoir tank (B) and the clip (C) from the bracket (D).

  1. Remove the bracket mount bolt (A) and the clip (B).

  1. Disconnect the brake lines (A) from the master cylinder (B). To prevent spills, cover the hose joints with rags or shop towels.
  1. Remove the master cylinder mounting nuts (C) and the washers (D).
  1. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the bake lines when removing the master cylinder.
  1. Except KE ABS model: Remove the rod seal (F) from the master cylinder.
    NOTE: During installation, set the new rod seal onto the master cylinder with its grooved side (G) toward the master cylinder.
  1. KE ABS model: Remove the O-ring (H) from the master cylinder.
    NOTE: Use the new O-ring during installation.
  1. Install the master cylinder in the reverse order of removal, and note these items:
  1. Spin the wheels to check for brake drag.
KE ABS model:
Except KE ABS model: