Brake Master Cylinder: Service and Repair

MASTER CYLINDER





COMPONENT

REMOVAL
1. Remove the fluid level warning device connector.
2. Detach the brake tubes from the master cylinder, and then install the plug.

CAUTION: If there is any brake fluid on any painted surface, wash it off immediately.





3. Remove master cylinder mounting nuts and then lift out the master cylinder.

DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.





2. After disconnecting the mounting screws, pry the reservoir free from the master cylinder.





3. Using a snap ring pliers, remove the retainer ring.





4. Remove the primary cylinder pin, pushing the primary piston with a screwdriver and remove the primary piston assembly.





5. Remove the secondary cylinder pin. Push the secondary piston with a screwdriver and remove the secondary piston assembly.

NOTE: Do not disassemble the primary and secondary piston assembly.

INSPECTION
1. Check the master cylinder bore for rust or scoring.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.

NOTE:
1. If the cylinder bore is damaged, replace the master cylinder assembly.
2. Wash the parts in alcohol

REASSEMBLY





1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.





3. Press against the pistons with a screwdriver and in stall the retainer ring.





4. With the piston pushed completely by a screwdriver, install the cylinder pin.
5. Mount two grommets.





6. Install the reservoir on the cylinder.

INSTALLATION
1. Install the master cylinder to the brake booster.
2. Install the booster and master cylinder to the dash panel.
3. Connect the brake tubes to the master cylinder.
4. Install the vacuum hose tightly.
5. Connect the operating rod to the brake pedal.
6. After filling the brake reservoir with the brake fluid, bleed the system.

CAUTION: Don't disassemble the brake booster.