Brakes & ABS


Pushrod Clearance Adjustment
NOTE: Master cylinder pushrod-to-piston clearance
must be checked and adjustments made, if necessary,
before installing master cylinder.
1. Set the special tool on the master cylinder body;
push in the center shaft until the top of it contacts
with the end of the secondary piston by turning the
adjusting nut.
2. Without disturbing the center shaft’s position, in-
stall the special tool upside down on the brake
3. Install the master cylinder nuts and tighten to the
specified torque.
4. Connect the brake booster in-line with a vacuum
gauge 0-760 mm Hg (0 -30 in Hg) to the
booster’s engine vacuum supply, and maintain a
engine speed that will deliver 500 mm Hg (20 in
Hg) vacuum.
5. With a feeler gauge, measure the clearance be-
tween the gauge body and the adjusting nut as
NOTE: If the clearance between the gauge body
and adjusting nut is 0.4 mm (0.02 in), the pushrod-
to-piston clearance is 0 mm. However, if the
clearance between the gauge body and adjusting
nut is O mm, the pushrod-to-piston clearance is 0.4
mm (0.02 in) or more. Therefore, it must be ad-
justed and rechecked.
6. If clearance is incorrect, loosen the star locknut and
turn the adjuster in or out to adjust.
• Adjust the clearance while the specified vacuum
is applied to the brake booster.
• Hold the clevis while adjusting.
7. Tighten the star locknut securely.
8. Remove the special tool, and install a new master
cylinder rod seal in the brake booster.
9. Adjust the pushrod length as shown if the booster
is removed.
10. Install the master cylinder (see page 19-12).
11. After installation, perform the following inspec-
tions and adjust if necessary.
• Brake pedal height (see page 19-4).
• Brake pedal free play (see page 19-4).