Disassembly and Assembly

Caution
^ Secure the master cylinder flange in a vise when necessary.
^ Replace the piston assembly, if necessary.

Disassembly
1. Remove the cap and drain the master cylinder reservoir. Remove the master cylinder.





2. Remove the level sensor with screwdriver.





3. Remove the reservoir attaching screw.
4. Carefully pry the reservoir out of the master cylinder.
5. Remove the reservoir seals from the master cylinder.





6. Push the primary piston into the master cylinder bore to ease the snap ring removal. Remove the primary piston snap ring and the primary piston.





7. Push the secondary piston into the master cylinder bore before removing the stop screw. Remove the secondary piston stop screw.
8. Remove the secondary piston assembly by gradually applying the compressed air into the cylinder.





Caution Use a rag to stop the secondary piston assembly. Do not use a petroleum based solvent, kerosene, or gasoline for cleaning the master cylinder parts. Their use as a cleaning agent can leave residues which can damage the rubber seals.

Assembly

Notice As the masse cylinder parts are assembled, they must be lubricated with a clean brake fluid.

1. Install new seals on the primary and secondary pistons.
2. Lubricate the secondary piston with a brake fluid and install.
3. Install the secondary piston stop screw and O-ring such like below.





Stopper screw and O-ring
a. Push the secondary piston assembly in fully.
b. Install and tighten a new O-ring and stop screw.
c. Push and release the piston to verify that it is held by the stop screw.
4. Install the primary piston.





5. Install the primary piston snap ring. Push the piston into the maser cylinder bore to ease snap ring installation.
6. Install new reservoir seals.
7. Install the reservoir.
8. Install the master cylinder in the vehicle and bleed the system.