The brake pedal in a vehicle is connected to the brake master cylinder by a pushrod. When the brake pedal is depressed, the pushrod drives the master cylinder piston inward, which forces the brake fluid outward through the brake lines and to the brakes on all four wheels. After removal of the master cylinder for repair or replacement, the pushrod must be removed so that it can be reused in the replacement master cylinder.
Remove the pushrod retaining bolt and nut from the brake pedal with a socket and ratchet. The pushrod is attached to the upper end of the brake pedal under the dashboard. Place the hardware aside for reuse.
Open the hood, and locate the brake master cylinder, which is usually mounted to the firewall on the driver's side. Remove the master cylinder reservoir cap. Remove the brake fluid from the reservoir with a syringe.
Spray penetrating fluid to the brake line fittings at the base of the master cylinder. Twist the fittings off with a tubing wrench once the fluid has soaked in for a few minutes. Observe the brake-light wiring connector on the master cylinder to determine how it should be removed. Remove the connector from the master cylinder by squeezing or lifting a release tab (if equipped) and pulling the connector straight out.
Remove the master cylinder retaining bolts from the firewall with a socket and ratchet. Remove the master cylinder from the vehicle, and place it in a vice.
Pull the pushrod straight out of the master cylinder by hand. Use a pair of locking pliers if the pushrod is stubborn, but do not damage the pushrod if you plan on reusing it.
