Master Cylinder Disassembly and Assembly

DISASSEMBLY
1. Thoroughly clean the master cylinder and the brake fluid reservoir.
2. Using a syringe or other equivalent tool, empty as much brake fluid as possible from the brake fluid reservoir.

CAUTION: When mounting master cylinder in vise, clamp the master cylinder only by the mounting flange. Do not clamp on primary piston, seal or body of master cylinder.





3. Mount master cylinder in a vise .





4. Using a pin punch, remove the 2 roll pins retaining brake fluid reservoir to master cylinder.

CAUTION: When removing the fluid reservoir from the master cylinder do not pry the reservoir off with a tool, damage to fluid reservoir may result.

Removing Fluid Reservoir:

5. Rock brake fluid reservoir from side to side while pulling upward to remove it from sealing grommets in master cylinder.

CAUTION: The brake fluid reservoir to master cylinder sealing grommets can not be reused. Discard the sealing grommets after removing them from the master cylinder.

Remove Seal Grommets:

6. Remove master cylinder-to-fluid reservoir sealing grommets from master cylinder.

ASSEMBLY
1. Lubricate the NEW brake fluid reservoir to master cylinder seal grommets with fresh clean brake fluid.





2. Install new seal grommets in the master cylinder.
3. Lubricate the fluid ports on the brake fluid reservoir with clean fresh brake fluid.

Installing Brake Fluid Reservoir:

4. Place fluid reservoir in correct position over seal grommets. Seat fluid reservoir into seal grommets/master cylinder using a rocking motion while firmly pushing down on fluid reservoir.





5. Make sure brake fluid reservoir is installed on master cylinder until bottom of reservoir touches the top of both seal grommets.
6. Using a pin punch install the 2 roll pins retaining the brake fluid reservoir to the master cylinder.
7. Bleed the master cylinder prior to mounting it in the vehicle.