Disassembly and Assembly
NOTE:
^ This master cylinder is not suitable for use on vehicles equipped with ABS.
^ Numbers in parentheses ( ) below refer to numbers in the corresponding illustrations.
DISASSEMBLE
1. Remove master cylinder assembly from vehicle. Removal and Installation
Master Cylinder - Not ABS:
2. After a thorough cleaning and visual inspection, clamp master cylinder in a soft-jawed vise.
3. Remove master cylinder to servo flange O-ring seal (8) and discard.
4. Grip outside of transfer housing (9) with suitable pliers. Carefully pull, working pliers in a back and forth rocking motion to ease housing off master cylinder. Discard housing and vacuum seal.
Master Cylinder - Not ABS:
5. Ease reservoir (10) out of master cylinder, ensuring two outlet ports on bottom of reservoir do not become damaged.
6. Withdraw both reservoir seals (11) from master cylinder inlet ports. Discard seals.
NOTE: Reservoir seals are different. Identify for installation reference.
7. Remove retaining ring and O-ring seal (12) from machined outer surface of master cylinder. Discard retaining ring and seal.
8. Remove guide ring (13), which supports primary plunger assembly, from mouth of master cylinder. Place aside for reassembly.
NOTE: This component is not normally part of a master cylinder service kit.
Master Cylinder - Disassemble:
9. Pull primary plunger assembly (14) out of master cylinder.
NOTE: The primary plunger assembly cannot be broken down any further and is serviced as a complete unit. Discard assembly.
10. The secondary plunger assembly will remain at bottom of master cylinder bore. Remove by tapping assembly on a piece of wood until plunger appears at cylinder mouth. Carefully remove plunger from bore.
Master Cylinder - Disassemble:
11. If swirl tube (16) was not expelled at same time as secondary plunger, repeat preceding step to remove it from master cylinder bore. Discard tube.
12. Clean all parts with unused brake fluid. Place cleaned parts onto a clean sheet of paper. Inspect cylinder bore and plungers for signs of corrosion, ridges and score marks. Provided working surfaces are in perfect condition, new seals from a Girling service repair kit, or equivalent, may be used.
13. Remove and discard secondary plunger (18) springs (A), seal retainer (B), recuperating seal/primary cup (C), washer (D) and "L" seal (E).
CAUTION: In order to avoid secondary plunger damage, use a small screwdriver with a rounded and polished end to remove "L" seal.
Secondary Plunger:
14. Coat new seals in unused brake fluid. Fit "L" seal (19) to secondary plunger.
15. Fit washer, then the recuperating seal (20). Install seal retainer and springs, ensuring springs are correctly seated.
ASSEMBLE
CAUTION: It is important that the following instructions are carried out precisely. Otherwise, damage to new seals may result when inserting plungers into cylinder bore. Generous amounts of new brake fluid should be used to lubricate parts during assembly.
1. Fit new swirl tube to bottom of cylinder bore.
Refitting Secondary Plunger:
2. Lubricate secondary plunger (22) and cylinder bore. Insert plunger assembly into cylinder until recuperation seal is resting centrally in mouth of bore. Gently continue inserting plunger, using a circular rocking motion as shown. Ensuring seal does not become trapped, ease seal into bore and slowly push plunger down in one continuous movement.
3. Install new primary plunger assembly in same fashion as secondary plunger.
4. Install original guide ring on support primary plunger.
5. Coat a new O-ring with brake fluid and fit into its respective groove on outer location surface of master cylinder.
CAUTION: Do not roll O-ring down outer surface of master cylinder. Stretch it slightly and ease it along surface until it reaches its groove. Do not overstretch seal.
6. Install new retaining ring on outer surface of master cylinder, ensuring serrations of ring face mounting flange.
7. Install two new reservoir seals in respective ports.
8. Install a new vacuum seal to either primary plunger or to bottom of transfer housing bore. Ensure open face of seal faces primary plunger.
9. Lubricate vacuum seal with brake fluid. Fit transfer housing to master cylinder and push housing fully up to cylinder mounting flange. Do not adjust transfer housing after installation.
10. Lubricate new water ingress seal with brake fluid. Stretch seal slightly and ease down housing until it is in position between housing and flange.
11. Roll reservoir into top of master cylinder. Ensure outlet ports are not damaged.
NOTE: Ensure O-ring seal between master cylinder and servo unit is fitted correctly.
12. Install master cylinder assembly. Removal and Installation