Overhaul

REMOVAL
1. Apply service brake pedal several times to exhaust all vacuum in the system.
2. Disconnect brake fluid level warning switch connector.
3. Remove brake tubes from primary and secondary outlet ports of brake master cylinder.
4. Remove nut retaining cowl top inner panel tube (02206) to brake master cylinder.
5. Disconnect cowl top inner panel tube from cowl and remove.
6. Remove two nuts retaining brake master cylinder to power brake booster assembly.
7. Slide brake master cylinder forward and upward from vehicle.





DISASSEMBLY
NOTE: If brake master cylinder is to be put into vise to aid in disassembly, mount into vise by flange only to avoid damage to bore or reservoir areas.

1. Clean outside of brake master cylinder thoroughly. Remove brake master cylinder filler cap.
2. Drain all brake fluid from brake master cylinder. Always discard used brake fluid.
3. Remove primary brake master cylinder reservoir port from brake master cylinder by prying upward with rod or long screwdriver.
4. Remove secondary brake master cylinder reservoir port in same manner

Snap Ring:

5. Depress primary piston and remove snap ring from retaining groove at open end of bore.

WARNING: USE ONLY AS MUCH COMPRESSED AIR AS NECESSARY TO REMOVE THE PISTON. EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT COMES OUT OF THE BORE.

6. Tap open end of brake master cylinder on bench to remove primary and secondary pistons. If secondary piston does not readily come out, carefully apply air pressure to secondary outlet port to assist removal.

ASSEMBLY
1. Dip replacement piston assemblies in clean DOT-3 motor vehicle brake fluid for lubrication prior to assembly into cylinder.
2. Install secondary piston (smaller) assembly into bore, spring end first.
3. Install primary piston assembly, spring end first.
4. Depress primary piston and install snap ring.
5. Install brake master cylinder filler cap on brake master cylinder reservoir and secure.

INSTALLATION
1. Position brake master cylinder on studs on power brake booster assembly.
2. Install retaining nuts. Tighten to 26-39 Nm (20-28 ft.lbs).
3. Connect cowl top inner panel tube to cowl.
4. Install nut retaining cowl top inner panel tube to brake master cylinder and tighten to 21-29 Nm (16-21 ft.lbs).
5. Install primary and secondary brake tubes to brake master cylinder outlet ports. Tighten to 16-20 Nm (12-14 ft.lbs).
6. Connect brake fluid level warning switch connector.
7. Fill brake master cylinder reservoir with specified brake fluid to MAX line with High Performance DOT-3 Motor Vehicle Brake Fluid.
8. Bleed brake system.