Reservoir Replacement

Disassembly
1. Remove master cylinder.
2. Remove reservoir caps and diaphragms.

Figure 6 Removing Master Cylinder Reservoirs:

3. Remove reservoirs (6).
a. Drain fluid.
b. Clamp one side of cylinder body flange in a vise. Do not clamp across master cylinder body (1).
c. Use a rocking motion to pull off reservoirs (6).
d. Remove body (1) from vise.
4. Remove grommets (2).

Assembly
1. Lubricate grommets (2) and inside neck of reservoir (6) with clean brake fluid.
2. Install new grommets (2) into reservoirs (6) by hand, pressing grommets (2) into reservoirs (6) until grommet flanges are flush against reservoirs (6).
3. Install reservoirs (6) and grommets (2) onto body (1).
a. Install pilot from special tool J 34121 (29) in reservoir port on master cylinder body (1). Lubricate OD of pilot (29) and cylinder body port with clean brake fluid.
b. Position reservoir (6) and grommet (2) over pilot (29).
c. Position installer from special tool J 34121 (30), open end down, into reservoir (6), seated on boss around grommet (2).

Figure 7 Installing Reservoirs:

d. Using an arbor press, press reservoir (6) and grommet (2) onto body (1) until flange of grommet (2) seats against body face.
e. Remove assembly from arbor press.
f. Remove installer (30) and pilot (29).

Figure 8 Checking Reservoir Seating:

g. Using installer (30), by hand, insure that reservoir (6) and grommet (2) are firmly seated on body (1).
h. Install second reservoir (6) and grommet (2) as described above.
4. Install master cylinder.