Master Cylinder Overhaul (ABS)

DISASSEMBLY PROCEDURE

CAUTION:
^ Refer to Brake Fluid Irritant Caution in Service Precautions.
^ Refer to Brake Fluid Caution in Service Precautions.

NOTICE:
^ Refer to Filling the Master Cylinder Notice in Service Precautions.
^ Refer to Honing The Master Cylinder Bore Notice in Service Precautions.
^ Refer to Master Cylinder Body Notice in Service Precautions.





1. Remove the reservoir (2) from the master cylinder (4).
2. Remove the master cylinder from the booster.





3. Remove the piston stopper snap ring (1) from the master cylinder (2).
4. Remove the piston stopper.
5. Remove the cylinder cup.
6. Remove the plate.
7. Pull the primary piston assembly carefully from the master cylinder in order to prevent damage to the inside of the cylinder wall.





8. Remove the secondary piston assembly carefully from the master cylinder (1) by tapping the flange on a piece of wood (2) or two soft objects.
9. Remove the secondary piston pressure cup.
10. Remove the piston cup.
11. Remove the O-ring.
12. Inspect all disassembled parts for wear or damage. Replace parts if necessary.

IMPORTANT: DO NOT reuse piston cups.

13. Wash disassembled parts with brake fluid.
14. Inspect the master cylinder bore for scoring or corrosion (pits or excessive roughness). Replace a corroded master cylinder.

IMPORTANT: Do NOT use a cloth in order to dry the cylinder, because lint from a cloth will stick to the cylinder bore surfaces.

15. Rinse the cylinder in clean brake fluid. Shake excess rinsing fluid from the cylinder.

ASSEMBLY PROCEDURE





1. Install the O-ring to the master cylinder (2).
2. Install the following to the master cylinder:
^ The new piston cup
^ The secondary piston assembly
^ The new secondary piston pressure cup

3. Install the primary piston assembly to the master cylinder.
4. Install the plate.
5. Install the cylinder cup.
6. Install the piston stopper.





7. Depress and install the piston stopper snap ring into the master cylinder (2).
8. Install the master cylinder to the brake booster.





9. Apply a thin coat of brake fluid around the new grommets (3), and install the grommets to the master cylinder (4).
10. Install the reservoir.