1500 4x2 Pickup V8-5.2L CNG VIN T (1996)
Brake Master Cylinder: Service and Repair
Master Cylinder Replacement
Without Aluminum Master Cylinder
1. Disconnect brake lines from master cylinder. Install plugs in outlets to prevent fluid leakage.
2. Remove nuts that attach master cylinder to cowl panel or power brake unit, if equipped.
3. Disconnect pedal pushrod (manual brakes) from brake pedal.
4. Slide master cylinder straight out from cowl panel and/or power brake unit.
5. Reverse procedure to install.
With Manual Brakes
1. Disconnect brake lines from master cylinder. Install plugs in outlets to prevent fluid leakage.
2. From under instrument panel, disconnect stop lamp switch mounting bracket and position aside.
3. Grasp brake pedal and pull backward to disengage pushrod from master cylinder piston. This will require a pull of about 50 lbs. Also, the
retention grommet will be destroyed.
4. Remove master cylinder to cowl retaining nuts and remove master cylinder by pulling straight out. Make sure to remove all traces of old
grommet from pushrod groove and master cylinder piston.
5. Reverse procedure to install. Install new grommet on pushrod, then lubricate grommet with water and align pushrod with master cylinder piston.
Using brake pedal, apply pressure to fully seat pushrod into piston.
With Power Brakes
1. Disconnect primary and secondary brake tubes from master cylinder, then cap lines and master cylinder fitting.
2. Remove nuts attaching master cylinder to power brake unit, then slide master cylinder from power brake unit.
3. Reverse procedure to install.
With ABS
1. Using a suitable flare nut wrench, remove brake lines from master cylinder to combination valve.
2. Disconnect brake line from the Rear Wheel Anti-Lock (RWAL) valve to combination valve.
3. Disconnect harness wires from RWAL valve and combination valve switch.
4. Disconnect anti-lock harness ground wire from combination valve bracket.
5. Remove nuts attaching combination valve bracket and master cylinder to brake booster mounting studs.
6. Slide combination valve bracket off of booster mounting studs, then remove master cylinder.
7. Reverse procedure to install, noting the following:
a. Ensure brake booster push rod is aligned and seated in primary piston.
