Master Cylinder Reservoir Replacement JH6

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

1. Apply the park brake and block the wheels.
2. Remove the master cylinder. Refer to Master Cylinder Replacement .
3. Drain the master cylinder reservoir.
4. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange.
5. Remove the brake fluid level sensor by carefully depressing the retaining tabs and pushing the sensor through the reservoir.
6. Carefully remove the reservoir retaining pins.



7. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder.
8. Remove the seals from the master cylinder.

1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir.
2. Clean the reservoir with denatured alcohol, or equivalent.
3. Dry the reservoir with non-lubricated, filtered air.
4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
5. Install the lubricated seals. Ensure that they are fully seated.
6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned.



7. Carefully install the reservoir retaining pins to secure the reservoir.
8. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs.
9. Remove the master cylinder from the vice.
10. Install the master cylinder. Refer to Master Cylinder Replacement .
11. Release the park brake.
12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

Master Cylinder Reservoir Replacement JD9

Master Cylinder Reservoir Replacement Two-mode Hybrid

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

Important: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes.

1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.

Important: During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process.

2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
3. Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container.
4. Disconnect the brake fluid level sensor electrical connector.



5. Disconnect the brake master cylinder reservoir return hose quick connect (1) and position the hose aside.
6. Disconnect the brake master cylinder reservoir supply hose quick connect (2) and position the hose aside.



7. Remove the brake master cylinder reservoir pins (1).



8. Lift the master cylinder reservoir (1) straight up and remove the reservoir from the master cylinder.



9. Remove the 3 master cylinder reservoir seals (1).

1. Install the 3 master cylinder reservoir seals (1).

Lubricate the master cylinder reservoir seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3  brake fluid from a clean, sealed brake fluid container.




2. Install the master cylinder reservoir (1) to the master cylinder.

Ensure the master cylinder reservoir is seated fully into the master cylinder by pressing the reservoir straight down into the master cylinder.

Notice: Refer to Fastener Notice in the Preface section.




3. Install the brake master cylinder reservoir pins (1).

Tighten
Tighten the pins to 8 N·m (71 lb in).




4. Connect the brake master cylinder reservoir return hose quick connect (1).
5. Connect the brake master cylinder reservoir supply hose quick connect (2).
6. Connect the brake fluid level sensor electrical connector.
7. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling .