Disassembly and Assembly

Master Cylinder Disassembly
1. Remove the master cylinder.
2. Remove the brake fluid reservoir.





3. Remove the screw from the cylinder.





4. Remove and discard the retaining ring from the cylinder body by pressing the hollow shaft and using needle-nosed pliers to grasp and squeeze the retaining ring.

CAUTION: When removing the retaining ring, avoid damaging the piston or the cylinder wall.





5. Remove the washer and the primary piston assembly.





6. Carefully remove the secondary piston assembly, including the spring, from the master cylinder bore.

Master Cylinder Assembly

CAUTION: Do not use abrasives in the master cylinder bore. Abrasives can damage the bore.

CAUTION: Rubber parts and retaining rings must be discarded and replaced with new parts.

1. Clean all the parts with denatured alcohol or clean brake fluid. Dry the parts with compressed air.
2. Inspect the master cylinder bore for scoring or corrosion. If scoring or corrosion is evident, replace the master cylinder body.





3. Lubricate the master cylinder bore with clean brake fluid.
4. Carefully insert the secondary piston assembly bore until the secondary piston contacts the base of the cylinder body. Use a wood or a plastic drift, if necessary.





5. Insert the primary piston assembly and the washer.
6. Press the pistons into the cylinder bore using a wooden or a plastic drift.





7. Insert the washer and the new retaining ring into the groove in the cylinder bore.

CAUTION: When installing the washer and the new retaining ring, take care not to damage the cylinder bore.





8. Install the retaining screw in the bottom of the master cylinder and tighten it until it bottoms out on the internal piston assembly.
9. Insert a new O-ring over the cylinder body.
10. Install the brake fluid reservoir.
11. Install the master cylinder.
12. Raise and suitably support the vehicle.
13. Bleed the brake system.





14. Lower the vehicle.