Disassembly Procedure
- Remove the master cylinder
assembly (5) and the reservoir (2). Refer to the following procedures:
- Remove the snap ring from
the master cylinder.
- Remove the following components
from the master cylinder:
| • | Primary piston stopper (9) |
- 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.
- Remove the following components by blowing dry compressed air into the
piston stopper bolt hole:
- Clean the reservoir inside
and out.
- Clean the master cylinder body (1) and all of the internal
parts using clean brake fluid.
- Dry the parts using dry, compressed air.
- Inspect the reservoir and the cap for the following conditions:
- 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.
- Inspect the master cylinder internal parts for wear. Replace the master
cylinder if wear is excessive.
Assembly Procedure
- Coat all of the parts with clean brake fluid.
- Install the following
components into the master cylinder body (2):
| • | Secondary piston spring (7) |
| • | Secondary spring seat (6) |
- Install the following components into the master cylinder body (2):
| • | Primary piston stopper (9) |
- Compress the pistons. Install the snap ring (8).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the piston
stopper washer and the bolt (3). Ensure that the pistons are pushed
in all the way.
Tighten
Tighten the piston stopper bolt (3) to 10 N·m (89 lb in).
- Bench bleed the master cylinder. Refer to
Master Cylinder Bench Bleeding
.
- Install the master cylinder
assembly (5) and the reservoir (2) to the vehicle.
Refer to the following procedures:
