Overhaul

NOTE: Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rubber components may result. If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque values specified are for dry, unlubricated fasteners.

DISASSEMBLY
1. Remove circlip.
2. Remove primary piston.





3. Remove piston stopper bolt. Then remove secondary piston by blowing compressed air into hole from which piston stopper bolt was removed. Be cautious during removal as secondary piston jumps out.

NOTE: Before assembling, wash each part in fluid recommended to
use for that vehicle.





INSPECTION
Inspect all disassembled parts for wear or damage, and replace parts if necessary.

NOTE: Wash disassembled parts with brake fluid and do not reuse piston cups.

Inspect master cylinder bore for scoring or corrosion. It is best to replace corroded cylinder. Corrosion can be identified as pits or excessive roughness.
Check for a cracked master cylinder casting or brake fluid around the master cylinder. Leaks are indicated only if there is at least a drop of fluid. A damp condition is not abnormal.

NOTE: Polishing bore or master cylinder with cast aluminum body with anything abrasive is prohibited, as damage to cylinder bore may occur.

Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot be kept from cylinder bore surfaces.

ASSEMBLY
1. Assemble secondary piston.
2. Install secondary piston assembly into cylinder.
3. Install primary piston in cylinder.





4. Depress, and install circlip.





5. Install piston stopper bolt and with pistons pushed in all the way and tighten it to (a): 10 Nm (7.5 ft. lbs.)