SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Warning: Brake fluid is very caustic and can damage paint, chrome and plastic. Wipe up any spills immediately.
Removal
Remove the brake pedal pinch bolt with a 10 mm socket.
Unhook the rear brake light switch spring from the rear brake pedal.
Remove the brake pedal pivot joint cotter pin.
Slide out the brake pedal pivot joint.
Remove the brake pedal.
The brake pedal pivot and return spring can now be removed.
Remove the two rear brake master cylinder reservoir cover screws using a #3 Phillips head screwdriver.
Remove the rear brake master cylinder reservoir cover.
Remove the rear brake reservoir mounting bolt using a 10 mm socket.
Remove the reservoir cap and rubber diaphragm. Pour the brake fluid into a suitable container.
Loosen the rear brake hose banjo bolt with a 12 mm socket.
Remove the rear brake banjo bolt and two sealing washers. Allow the brake fluid to drain into a suitable container. Discard the old sealing washers.
Remove the two Allen bolts that hold the rear master cylinder to the frame using a 6 mm Allen wrench.
Remove the rear brake master cylinder.
Disassembly and Inspection
Squeeze and slide back the reservoir clamp with needle nose pliers.
Remove the snap ring that holds the reservoir pipe to the master cylinder using a pair of internal snap ring pliers.
Remove the reservoir pipe and O-ring. Replace the O-ring as needed.
Pull back the rubber boot. Remove the snap ring that holds the rear master cylinder brake rod to the master cylinder using a pair of internal snap ring pliers.
Remove the rear master cylinder brake rod.
Remove the plunger, rubber cup seal and the spring. Inspect the master cylinder bore fore wear and damage.
Inspect the plunger seal and cup seal for tears or other damage. Replace as necessary.
Assembly
Clean all of the rear master cylinder components with aerosol brake cleaner and a lint free cloth. Coat the plunger and seal with DOT 4 from a sealed container. Also coat the cup seal, spring and plunger bore with brake fluid.
Install the spring into the master cylinder, large end first, then the cup seal, open end first. Make sure not to cock the cup seal sideways. Install the plunger, spiral end first.
Push the plunger in against the spring tension with the brake rod and install the snap ring. Use internal snap ring pliers and make sure the snap ring is seated fully in its groove.
Place the rubber boot back in position.
Install the reservoir pipe and O-rings.
Install the reservoir pipe snap ring with snap ring pliers.
Slide the reservoir hose back onto the pipe. Secure the hose with the clamp.
Installation
Set the rear brake master cylinder in place.
Install the two Allen bolts that hold the rear master cylinder to the frame. Tighten the bolts to specification using a 6 mm Allen socket.
| Fastener | Torque | |
| N-m | ft-lb | |
| Rear Master Cylinder Mounting Bolts | 23 | 16.5 |
Install the brake hose banjo bolt using new sealing washers. Make sure to put one sealing washer on each side of the banjo fitting.
Torque the banjo bolt to specification with a 12 mm socket.
| Fastener | Torque | |
| N-m | ft-lb | |
| Brake Hose Banjo Bolts | 25 | 18 |
Fit the rear brake reservoir into place and insert the mounting bolt. tighten the mounting bolt to specification with a 10 mm socket.
| Fastener | Torque | |
| N-m | ft-lb | |
| Rear Master Cylinder Reservoir Tank Mounting Bolt | 6.9 | 61 in-lb |
Fill and bleed the rear brake fluid. See the Rear Brake Bleeding topic for more information.
Install the rear brake reservoir cover.
Insert the two rear brake reservoir cover screws and tighten them securely with a #3 Phillips screwdriver.
Check the function or the rear brake and brake light before returning the vehicle to operation.