Master Cylinder Disassembly/Assembly

Figure 5A-1 Exploded View Of Master Cylinder Assembly:

Disassembly
1. Remove the dust seal.
2. Remove the reservoir screw.
3. Remove the reservoir from the master cylinder body.
4. Remove the two grommets from the master cylinder.

Figure 5A-3 Removing/Installing Proportioning Valves:

5. Remove the proportioning valves.

Figure 5A-4 Removing/Installing Stopper Bolt:

CAUTION: Do not damage piston or cylinder wall.

6. Use a screwdriver to fully depress the pistons and remove the piston stopper bolt.

Figure 5A-5 Removing/Installing Snap Ring:

7. Remove the snap ring with a pair of snap ring pliers.
8. Remove primary and secondary piston assemblies.

Inspection:
1. Inspect the following parts for wear, cuts, corrosion, or other abnormal conditions:
- Cylinder body
- Proportioning valve
- Reservoir
- Primary piston - cups and spring
- Secondary piston - cups and spring
- Grommets

2. Check the inlet port and return port for obstructions and, if necessary, clean with tag wire. Blow away any foreign matter with compressed air.

Assembly
1. Apply rubber grease to the piston cups.
2. Insert the piston straight in, not at an angle.

CAUTION: Be careful not to scratch the piston cups when installing the piston assemblies.

3. Install the snap ring while pushing in the piston.
4. Use a screwdriver to fully depress the pistons and install the piston stopper bolt.
5. Torque piston stopper bolt to 7.85 Nm (5.78 ft. lbs.)
6. Install the proportioning valves and torque to 39.2 Nm (28.9 ft. lbs.)
7. Push the reservoir onto the master cylinder body and install the reservoir screw.
8. Torque the reservoir screw to 1.47 Nm (1.08 ft. lbs.)

Figure 5A-6 Dust Seal Position:

9. Install the dust seal with the notch at the bottom.