Honda Element. Manual - part 328

Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. M/T model: Remove the clutch reservoir bracket from the vehicle, and move it aside. Do not disconnect 

the clutch hose from the reservoir.  

3. Remove the reservoir cap and brake fluid from the master cylinder reservoir with a syringe.  

4. Remove the brake fluid level switch connector (A). 

Fig. 35: Identifying Brake Fluid Level Switch Connector, Brake Lines, Master Cylinder And 
Master Cylinder Mounting Nuts With Torque Specifications 
Courtesy of AMERICAN HONDA MOTOR CO., INC. 

5. Disconnect the brake lines (B) from the master cylinder (C). To prevent spills, cover the hose joints with 

rags or shop towels.  

6. Remove the master cylinder mounting nuts (D) and washers.  

7. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines 

when removing the master cylinder.  

8. Remove the rod seal (F) from the master cylinder.  

9. Install the master cylinder in the reverse order of removal, and note these items: 



Replace all the rubber parts with new ones whenever the master cylinder is removed.  



Check the pushrod clearance before installing the master cylinder, and adjust it if necessary (see 
MASTER CYLINDER INSPECTION ).  



Use a new rod seal on reassembly.  



Coat the inner bore lip and outer circumference of the new rod seal with the Shin-Etsu silicone 
grease (P/N 08798-9013).  



Install the rod seal onto the master cylinder with its grooved side (G) toward the master cylinder.  



Check the brake pedal height and free play after installing the master cylinder, and adjust it if 
necessary (see BRAKE PEDAL AND BRAKE PEDAL POSITION SWITCH 
ADJUSTMENT ).  

10. Bleed the brake system (see BRAKE SYSTEM BLEEDING ).  

11. Spin the wheels to check for brake drag. 

 

2007 Honda Element EX 

2007-2008 BRAKES Conventional Brake Components - Element

  

MASTER CYLINDER INSPECTION

1. Inspect and note these items: 



Before reassembling, check that all parts are free of dirt and other foreign particles.  



Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with 
a new part if necessary.  



Do not allow dirt or foreign matter to contaminate the brake fluid. 

Fig. 36: Identifying Reservoir Cap, Reservoir Seal, Strainer, Reservoir And Master Cylinder
Courtesy of AMERICAN HONDA MOTOR CO., INC. 

BRAKE BOOSTER PUSHROD CLEARANCE ADJUSTMENT 

Special Tools Required  

Pushrod adjustment gauge 07JAG-SD40100 

1. Set the pushrod adjustment gauge (A) on the master cylinder body (B), push in the center shaft (C) until 

the top of it contacts the end of the secondary piston (D) by turning the adjusting nut (E). 

NOTE:

Brake booster pushrod-to-piston clearance must be checked and adjustments 
made, if necessary, before installing the master cylinder.

 

2007 Honda Element EX 

2007-2008 BRAKES Conventional Brake Components - Element

  

Fig. 37: Pushing Center Shaft 
Courtesy of AMERICAN HONDA MOTOR CO., INC. 

2. Without disturbing the center shaft's position, install the pushrod adjustment gauge (A) backwards on the 

booster. 

Fig. 38: Installing Pushrod Adjustment Gauge On Booster With Torque Specification 
Courtesy of AMERICAN HONDA MOTOR CO., INC. 

3. Install the master cylinder nuts (B), and tighten them to the specified torque.  

4. Connect the booster in-line with a vacuum gauge (C) 0-101 kPa (0-760 mmHg, 0-30 in.Hg) to the 

booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mmHg, 20 
in.Hg) vacuum.  

5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B) as 

shown. 

If the clearance between the gauge body and the adjusting nut is 0.4 mm (0.02 in.), the pushrod-to-piston 
clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is 0 mm, the 
push rod-to-piston clearance is 0.4 mm (0.02 in.) or more. Therefore it must be adjusted and rechecked. 

Clearance: 0-0.4 mm (0-0.02 in.)  

 

2007 Honda Element EX 

2007-2008 BRAKES Conventional Brake Components - Element

  

Fig. 39: Measuring Clearance Between Gauge Body And Adjusting Nut 
Courtesy of AMERICAN HONDA MOTOR CO., INC. 

6. If the clearance is incorrect, loosen the star locknut (A), and turn the adjuster (B) in or out to adjust. 



Adjust the clearance while the specified vacuum is applied to the booster.  



Hold the yoke (C) while adjusting. 

Fig. 40: Adjusting Clearance With Torque Specification 
Courtesy of AMERICAN HONDA MOTOR CO., INC. 

7. Tighten the star locknut securely.  

8. Remove the pushrod adjustment gauge (D).  

9. Check the pushrod length (A) as shown if the booster is removed. If the length is incorrect, loosen the 

pushrod locknut (B), and turn the yoke (C) in or out to adjust. 

 

2007 Honda Element EX 

2007-2008 BRAKES Conventional Brake Components - Element