4 - 12 BRAKES
GEM Service Manual November 2007
MASTER CYLINDER
ASSEMBLY
DESCRIPTION
The master cylinder assembly is located under the
hood on the left frame rail, next to the steering
column. A plastic reservoir on top of the master
cylinder holds additional brake fluid for proper
operation.
Fig. 8 Master Cylinder
1 - Reservoir
2 - Cap
3 - Maximum fluid level line
4 - Minimum fluid level line
5 - Brake pressure switch
6 - Brake failure switch
OPERATION
Pressure from the brake pedal is transmitted by a
push rod to a piston in the master cylinder, causing
the piston to move forward. Movement of piston
forces brake fluid out of master cylinder into brake
lines leading to the four brake assemblies.
REMOVAL
1. Remove upper and lower dash panel. See
Dash Panel Upper in Body section.
2. Remove the brake pedal to push rod bolt.
3. Disconnect the electrical connectors from the
master cylinder.
4. Using a flare nut wrench, remove the brake
lines from master cylinder. Cap the brake tube
connections to prevent fluid loss or dirt
contamination.
5. Remove two mounting bolts attaching master
cylinder to cowl.
6. Remove master cylinder and mounting gasket.
INSTALLATION
1. Install master cylinder and mounting gasket on
cowl.
2. Install the two mounting bolts and nuts. Tighten
to 225 in-lb.
3. Remove the brake line caps and install brake
lines to master cylinder.
4. Connect the electrical connectors to the master
cylinder.
5. Install the brake pedal to push rod bolt. Tighten
the bolt to 30 ft-lb.
6. Add DOT 3 brake fluid to master cylinder
reservoir until FULL line on side of reservoir is
reached.
7. Bleed brakes. See Brake Bleeding in this
section.
8. Install the upper dash panel. See Dash Panel
Upper in Body section.
TORQUE SPECIFICATIONS
Description Thread Size Use
Loctite®
242
Inch-
Pounds
Foot
Pounds
Brake line to wheel/master cylinder
--- NO 37 ---
Brake master cylinder to frame
5/16 – 18 NO 225 ---
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