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Master Cylinder: Disassembly

WARNING: This page is about a different car, the 2002 Pontiac Firebird and 2002 Chevrolet Camaro. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following actions: Eye contact, rinse thoroughly with water. Skin contact, wash with soap and water. If ingested, consult a physician immediately.
NOTE: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid.
  1. Remove the brake master cylinder from the vehicle. See MASTER CYLINDER  under REMOVAL & INSTALLATION. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible.
  2. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Remove the reservoir cap and diaphragm from the reservoir.
  3. Inspect the reservoir cap and diaphragm for cuts, cracks, nicks or deformation. If any of these conditions are present, replace the affected components.
  4. Remove the master cylinder reservoir from the master cylinder. See MASTER CYLINDER RESERVOIR  under REMOVAL & INSTALLATION. Using a smooth, round-ended tool, depress the primary piston and remove the piston retainer. See Figure .
  5. Remove the primary piston assembly from the cylinder bore. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston with the primary and secondary seals, and the return spring. See Figure .
  6. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston.
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