Master Cylinder Overhaul

Disassembly Procedure





1. Remove the master cylinder assembly (5) and the reservoir (2). Refer to the following procedures:
- Master Cylinder Replacement
- Master Cylinder Reservoir Replacement





2. Remove the snap ring from the master cylinder.





3. Remove the following components from the master cylinder:
- Primary piston stopper (9)
- Cylinder cup (10)
- Plate (11)
- Primary piston (12)
4. Remove the piston stopper bolt (3) and the washer from the master cylinder (2).

Caution: Be careful when blowing the secondary piston out of the master cylinder with compressed air. The piston can exit the cylinder with explosive force.

5. Remove the following components by blowing dry compressed air into the piston stopper bolt hole:
- Secondary piston (5)
- Spring seat (6)
- Spring (7)





6. Clean the reservoir inside and out.
7. Clean the master cylinder body (1) and all of the internal parts using clean brake fluid.
8. Dry the parts using dry, compressed air.
9. Inspect the reservoir and the cap for the following conditions:
- Cuts
- Cracks
- Deformation
10. Inspect the master cylinder body for scoring or corrosion. Replace the master cylinder if these conditions are present.

Important: Replacement internal parts for the master cylinder are available only as a complete piston set. If any of the master cylinder internal parts need to be replaced, replace all of the parts.

11. Inspect the master cylinder internal parts for wear. Replace the master cylinder if wear is excessive.


Assembly Procedure





1. Coat all of the parts with clean brake fluid.
2. Install the following components into the master cylinder body (2):
- Secondary piston spring (7)
- Secondary spring seat (6)
- Secondary piston (4)
3. Install the following components into the master cylinder body (2):
- Primary piston (12)
- Cylinder cup (10)
- Plate (11)
- Primary piston stopper (9)
4. Compress the pistons. Install the snap ring (8).

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the piston stopper washer and the bolt (3). Ensure that the pistons are pushed in all the way.
- Tighten the piston stopper bolt (3) to 10 Nm (89 inch lbs.).
6. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding.





7. Install the master cylinder assembly (5) and the reservoir (2) to the vehicle. Refer to the following procedures:
- Master Cylinder Replacement
- Master Cylinder Reservoir Replacement