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Master Cylinder: Reassembly

  1. Clamp cylinder housing in a vise fitted with soft (aluminum) jaws. Guide assembly sleeve with long neck pipe into cylinder bore.
  2. Slide stepped short neck pipe into cylinder bore against shoulder and hold in this position.
  3. Carefully press contents of assembly sleeve into cylinder bore with a suitable mandrel until the secondary piston touches bottom of the cylinder.
  4. Hold secondary piston against stop and screw in stop screw with a new aluminum seal. Tighten to specification. See TORQUE SPECIFICATIONS  .
  5. Release push rod piston carefully and slide on stop washer.
  6. Coat secondary cup with silicone grease and install.
  7. Let short stepped end of assembly sleeve protrude and slide over secondary cup. Hold cup with two fingers.
  8. Adjust secondary cup flush with long neck pipe and slide complete assembly sleeve into cylinder bore. Slide in long neck pipe carefully until resistance is felt.
  9. Hold long neck pipe and pull back short neck pipe.
  10. Remove complete assembly sleeve. Give plastic sleeve a light coat of silicone grease and slide on to push rod piston in cylinder bore.
  11. Press in push rod piston and plastic sleeve.
  12. Install circlip with a special circlip pliers. Circlip must have perfect fit in groove of cylinder bore.
  13. Install new seal before attaching on the vacuum brake booster.
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