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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1363 (Hydraulic Brake System) >> Repair Instructions >> Master Cylinder Overhaul >> Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different car, the 2004 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Master Cylinder Components
    GM830248Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Brake Fluid Irritant Caution in Cautions and Notices.
    CAUTION: Refer to Brake Fluid Caution in Cautions and Notices.
    NOTE: Refer to Filling the Master Cylinder Notice in Cautions and Notices.
    NOTE: Do not hone the master cylinder bore. When the brake master cylinder is overhauled, it is recommended that the cylinder body be replaced rather than CLEANED UP by honing the bore. The master cylinder has a hard, highly polished BEARINGIZED surface, which is produced by diamond boring followed by ball or roller burnishing under heavy pressure. Honing will destroy this hard smooth surface and cause rapid wear of the rubber cups.
  1. Remove the master cylinder (6) from the vehicle. Refer to Master Cylinder Replacement (Non-ABS)  or Master Cylinder Replacement (ABS) .
  2. Remove the 2 grommets (4,7).
  3. Remove the O-ring from the master cylinder bore.
    4. Fig 2: Pushing Master Cylinder Piston
    GM815504Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not clamp on the master cylinder body. Doing so may damage the master cylinder.
  4. Place the master cylinder in a vise.
  5. Push the piston into the master cylinder and remove the piston stopper bolt and the gasket.
    6. Fig 3: Removing Master Cylinder Snap Ring
    GM815506Courtesy of GENERAL MOTORS CORP.
  6. Push the piston into the master cylinder and remove the snap ring.
    7. Fig 4: Master Cylinder Components
    GM830251Courtesy of GENERAL MOTORS CORP.
  7. Remove the following components from the master cylinder:
    1. The plate (7)
    2. The cylinder cup (8)
    3. The O-ring (9)
    4. The piston guide (10)
    5. The primary piston and spring (11)
  8. Remove the master cylinder from the vise.
    9. Fig 5: Taping Cylinder Flange
    GM239139Courtesy of GENERAL MOTORS CORP.
  9. Place a rag and 2 wooden blocks on a table. Allow 100 mm (3.94 in) between the top of the rag and the top of the blocks (1) for the secondary piston.
  10. Tap the cylinder flange against the blocks in order to remove the secondary piston and spring.
  11. Wash the disassembled parts with clean brake fluid.
    12. NOTE: Do not use lubricated compressed air on brake parts as damage to rubber components may result.
  12. Dry the parts with compressed air.
  13. Inspect the parts for wear or damage. Replace any worn or damaged parts.
  14. Inspect the master cylinder bore for scoring or corrosion. Replace a damaged master cylinder.
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