Master Cylinder Disassembly/Assembly

Exploded View Of Master Cylinder Assembly:

Disassembly
1. Remove master cylinder assembly from vehicle.
2. Clamp master cylinder assembly in vice and remove reservoir (2).

Figure 5 Removing Seal Ring:

Figure 6 Depressing Piston:

3. Remove seal ring (9) out of cylinder bore.
4. Press pistons (6 and 7) approximately 10 mm (0.4 in.) into cylinder bore using suitable wooden or plastic drift.

NOTE: To keep pistons depressed, insert a piece of 3 mm (0.12 in.) diameter welding rod or equivalent into compensating port.

Figure 7 Removing Retaining Ring:

5. Force retaining ring (8) out of master cylinder body (5) using suitable screwdriver.

CAUTIONS:
^ Do not damage piston or cylinder wall.
^ Retaining ring (8) must not be reused.

6. Press pistons (6 and 7) into cylinder bore with wood/plastic drift and remove welding rod.
7. Remove primary piston (7) from cylinder bore by knocking cylinder body (5) against a piece of wood until piston can be removed.

Figure 8 Removing Secondary Piston:

8. Carefully remove secondary piston (6) from cylinder bore using compressed air.

Clean:
- All parts with clean brake fluid or denatured alcohol.
- Dry with compressed air.

9. Inspect master cylinder bore for scoring or corrosion. If noted, replace master cylinder. No abrasives shall be used in the bore.

CAUTION: Rubber parts and retaining rings (8) must not be reused once removed.

Assembly

1. Lubricate master cylinder bore with clean brake fluid.
2. Clamp cylinder body (5) in vice with reservoir bores facing up.
3. Carefully insert secondary piston assembly (6) bore until secondary piston contacts base of cylinder body (5). Use wood/plastic drift.
4. Insert primary piston (7).

NOTE: Depress pistons (6 and 7) and insert welding rod or equivalent into compensating port to retain pistons for retaining ring (8) installation.

5. Insert new retaining ring (8) in groove in cylinder bore.


CAUTION: Do not damage cylinder bore.

6. Press pistons (6 and 7) into cylinder bore using wooden or plastic drift and remove welding rod.
7. Move pistons backward and forward after installation to check for free movement.
8. Lubricate seal ring (9) and insert in cylinder bore with open side facing outward until it rests on piston.
9. Install master cylinder assembly and torque attaching nuts to 18 Nm (13 lbs. ft.)
10. Bleed brakes.