Master Cylinder Disassembly/Assembly

Exploded View Of Composite Master Cylinder:

Disassembly
1. Remove master cylinder from vehicle.
2. Remove reservoir cover and diaphragm. Discard old brake fluid in reservoir.
3. Inspect cover and diaphragm. Replace if cut, cracked or deformed.

CAUTION: Do not damage piston or cylinder wall.

4. Depress primary piston and remove lock ring.
5. Plug primary fluid outlet (outlet nearest to cowl when master cylinder is installed), then apply compressed air into secondary fluid outlet to remove primary and secondary pistons.
6. Remove spring retainer and seals from secondary piston.

Removing Master Cylinder Reservoir:

7. Clamp master cylinder in a vise, then remove reservoir using a pry bar. Remove reservoir grommets.

CAUTIONS:
^ Do not clamp on master cylinder body, instead clamp on mounting flange.
^ Do not remove quick take-up valve from body. The valve is not serviceable separately.

8. Inspect master cylinder bore for corrosion.

NOTE: Do not use abrasive material on master cylinder bore. Replace if bore is corroded.

Assembly
1. Clean all parts in clean denatured alcohol. Dry with compressed air.
2. Lubricate new reservoir grommets with brake fluid, then press grommets into master cylinder body. Ensure grommets are properly seated.

Installing Reservoir:

3. Lay reservoir upside down on flat, hard surface. Press master cylinder body onto reservoir using rocking motion.
4. Lubricate new seals with brake fluid and install on secondary piston.
5. Install spring, spring retainer and secondary piston assembly into cylinder.
6. Lubricate seals then install primary piston. Depress primary piston into cylinder, then install lock ring.
7. Fit diaphragm into reservoir cover, then install cover onto reservoir.
8. Install master cylinder in vehicle.