Master Cylinder

Removal
1. Remove stepped tandem brake master cylinder

Dismantling, Assembling
2. Dismantle stepped tandem brake master cylinder as follows:





1. Slightly press in piston (3) using a suitable alignment tool and withdraw cylindrical pin (27) using suitable pliers.





2. Remove locking ring (5) and remove piston (3) together with secondary seal package from the housing (22).
3. Knock out the complete piston for the floating circuit by applying light blows to the housing (22) placed on a wood support.
4. Clean housing and check surface of housing bore for damage.
If the housing bore is scored or damaged. Replace brake master cylinder completely.
5. Clean all parts thoroughly with new brake fluid. Ensure that all residues are flushed out of the brake fluid reservoir.
3. Assemble stepped tandem brake master cylinder.

NOTE: Repair kits and housing of various manufacturers may be used as an alternative.





1. Separate packing sleeves (040) from sleeve (041).
2. Remove secondary seal package and piston for the thrust rod circuit from the sleeve (041).





3. Clamp housing (22) inclined slightly, with the bare pointing downwards.
4. Smear bore of housing (22) lightly with brake fluid.
5. Insert packing sleeve (040) into the bore and push in floating piston (20) up to the stop @ using a screwdriver.
- When installing the floating piston (20) ensure that the guide slot (arrow) is vertical.
6. Insert cylindrical pin and withdraw packing sleeve (040).
7. Clamp tandem brake master cylinder so that the bore points upwards.
8. Insert secondary sealing package into the housing (22) and press downwards using an alignment tool.





9. Hold piston (7) securely, insert stop disc (8) and mount locking ring (5).
- Ensure that the locking ring (5) is correctly located in the groove of the housing (22).
10. Smear reservoir plugs (9) lightly with brake fluid and press into the housing (22).
11. Initially, insert brake fluid reservoir (10) with only one pipe connection into the housing (22), turn through 180° and then press the second pipe connection into the housing (22).