1987 Toyota Pickup: How to Change Out the Master Brake Cylinder

Though the Tacoma and the Tundra get all of the fame, the first Toyota pickup sold in the U.S. was the Stout in 1964. The Stout was short-lived, as Toyota discontinued it in 1967 and replaced it with the Hi-Lux in 1969. With no explanation, Toyota kept the Hi-Lux body, but eliminated the Hi-Lux name in the U.S. in favor of the uncreative Pickup name Hi-Lux remained throughout the rest of the world. The 1987 Toyota Pickup came standard with power hydraulic brakes, which used a master cylinder to create pressure in the brake lines. When replacing the master cylinder, you must bench-bleed it before installation.

Instructions

Changing the Master Cylinder

1

Pull the cap off the master cylinder reservoir. Siphon all of the fluid from the reservoir with a clean turkey baster. Transfer this fluid to a small, sealable container.

2

Position a small drain pan under the master cylinder and loosen the steel brake line running into the master cylinder with a line wrench. Allow the fluid to drain from the lines into the drain pan, then remove the lines from the master cylinder. Wrap the end of each line with a clean, lint-free cloth to prevent debris from getting into the hydraulic system.

3

Press and hold the unlocking button on the wiring harness plugging into the master cylinders brake fluid level sensor wiring, if so equipped, and unplug the harness.

4

Remove the four master cylinder-retaining nuts with a ratchet and socket. Pull the master cylinder from the brake booster.

5

Set the new master cylinder in a bench vise with rubber jaw protectors installed. Tighten the bench vise until it holds the master cylinder in place. Hand-thread bleeder hoses into the brake line ports on the master cylinder, then snug them with a line wrench.

6

Route the bleeder lines into the master cylinder reservoir and fill the reservoir to the Max line with new DOT 3 brake fluid position the bleeder hoses so the ends are in the reservoir to submerge them in the brake fluid.

7

Press and release the plunger on the rear of the master cylinder with a wooden dowel rod and watch the ends of the bleeder hoses in the brake fluid for bubbles. Repeat this step until no bubbles come from the hoses.

8

Unscrew the bleeder hoses with a line wrench and remove them from the master cylinder. Press the cap onto the master cylinder.

9

Set the new boot included with the new master cylinder onto the raised section on the rear of the new master cylinder with the Up marking facing up. Set the master cylinder on the brake booster, guiding the mounting studs on the booster through the mounting holes in the master cylinder. Hand-thread the nuts onto the mounting studs.

10

Hand-tighten the brake lines into the ports on the master cylinder.

11

Torque the master cylinder-retaining nuts to 9 foot-pounds with a torque wrench and socket. Tighten the brake lines to 11 foot-pounds with a torque wrench and crows foot attachment.

12

Plug the brake fluid level wiring harness back into the Toyotas wiring harness.

Bleeding the Brake System

13

Raise the front of the truck with a floor jack and slide jack stands under the trucks frame rails. Lower the truck onto the jack stands. Raise the rear of the truck with a floor jack and place jack stands under the rear axle.

14

Crawl under the right rear wheel and find the brake bleeder valve the 1/4-inch metal valve on the top of the drum backing plate. Press a 1/4-inch diameter rubber hose onto the bleeder valve and set the other end in a clean, clear container. Fill the container with fresh DOT 3 brake fluid until fluid submerges the end of the hose.

15

Instruct an assistant to press and release the brake pedal slowly until the pedal feels firm. Tell your assistant to hold firm downward pressure on the pedal. Turn the bleeder valve a quarter-turn counterclockwise with a combination wrench to open it. Look at the end of the hose in the brake fluid and look for air bubbles. Repeat this step until no bubbles appear.

16

Remove the rubber hose from the bleeder valve. Refill the master cylinder to the Max line with fresh DOT 3 brake fluid.

17

Repeat steps 2 through 4 to bleed the remaining three wheels, in the following order: left rear, right front and left front. On the front wheels, the bleeder valve is on the rear of the brake caliper, as they are disc brakes.

18

Raise the rear of the truck off the jack stands with a floor jack and remove the jack stands. Lower the rear of the truck to the ground. Raise the front of the truck off the jack stands with a floor jack and remove the jack stands. Lower the front of the Toyota to the ground.

19

Take any old brake fluid to an automotive fluid recycling center for disposal. Some auto parts stores take old fluid for free.