Master Cylinder Overhaul

REMOVAL PROCEDURE
1. Remove the master cylinder from the vehicle.





2. Remove the reservoir pin (1) using a hammer and a punch.





3. Remove the reservoir (1) and grommets (3) from the master cylinder (4).





4. Remove the snap ring from the master cylinder (2).





5. Remove the primal, piston stopper (14), the cylinder cup (13) and plate (12) and the primary piston (11) from the master cylinder (1).





6. Remove the piston stopper bolt (2) and washer from the master cylinder (1).

CAUTION: Be careful when blowing the secondary piston out of the master cylinder with compressed air. The piston can exit the cylinder with explosive force.

7. Remove the secondary piston, the spring seat and the spring by blowing dry compressed air into the piston stopper bolt hole.
8. Clean the following parts:

- The reservoir, inside and out.
- The master cylinder body and all of the internal parts with clean brake fluid.
- Dry all parts with dry, compressed air.

IMPORTANT: Replacement internal parts for the master cylinder are available only as a complete piston set. Should any of the master cylinder internal parts need to be replaced, replace them all.
9. Inspect the following parts:

- The reservoir and cap for cuts, cracks and deformation.
- The master cylinder body for scoring or corrosion. If these conditions are noted, replace the master cylinder.
- The master cylinder internal parts for wear. Replace the master cylinder if the wear is excessive.

INSTALLATION PROCEDURE
1. Coat all of the parts with clean brake fluid.





2. Install the secondary piston spring (5), the spring seat (6) and the piston (8) into the master cylinder body (1).
3. Install the primary piston (11), the cylinder cup (13) and plate (12), and the piston stopper (14) to the master cylinder body (1).





4. Compress the pistons and install the snap ring (1).

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.






5. Install the piston stopper washer and bolt (12) with the pistons pushed all the way in.
^ Tighten the piston stopper bolt to 10 Nm (89 inch lbs.).





6. Coat the new reservoir grommets with clean brake fluid.
7. Install the reservoir grommets (3) to the master cylinder (4). Make sure the grommets seat properly.





8. Install the reservoir (2) to the master cylinder (3). Secure the reservoir by driving the reservoir pin in using a drift.
9. Install the master cylinder assembly to the vehicle.