Group 23, Brake System
23-5-2 • Pedal and Master Cylinder Service (Removal, Replacement, and Adjustment)
SM 765, Nov ’06
Components Disassembly
Use Figures 1, 2, and 3 as guide to disassembly and
adjustment.
Components Reassembly
Replace the brake pedal components as shown in Figures
1 and 2 using fastener torques where shown. Also use the
following notes:
1. Clean the reservoir and master cylinder hoses and fit-
tings. Make sure no contaminants enter the braking
system.
2. Adjust pedal free play as described in “Pedal Adjust-
ment” on the page.
3. After re-assembly and adjustment, the brake system
must be bled, see Section 2 in this Group. After
bleeding, check all fluid connections for leaks and
test brakes completely before returning truck to ser-
vice.
Freeplay Adjustment
When the brake pedal linkage is properly adjusted, brak-
ing should begin only after the pedal is depressed a certain
distance, This is “Freeplay” is Adjusted as follows :
1. Loosen the jam nut on the rod brake master cylinder
(Figure 1).
2. Depress the brake pedal 4~6mm (0.16~0.24 in).
3. Adjust the rod until you feel the push rod make clear-
ance with the cylinder piston.
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