Master Cylinder: Reassembly
WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
Do not use abrasives to clean the brake master cylinder bore.
- Clean the interior and exterior of the master cylinder, the secondary piston, and the return spring in denatured alcohol, or equivalent. See Figure.
- Inspect the master cylinder bore, inlet and outlet ports, the secondary piston, and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist.
- Dry the master cylinder and the individual components with non-lubricated, filtered air.
- Lubricate the master cylinder bore, the secondary piston, the return spring, and all of the individual overhaul components with Delco Supreme 11®, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
- Assemble the lubricated, NEW primary seal and retainer, and NEW secondary seal onto the secondary piston.
- Install the lubricated return spring and secondary piston assembly into the cylinder bore.
- Install the lubricated, NEW primary piston assembly into the cylinder bore.
- Using a smooth, round-ended tool, depress the primary piston and install the NEW piston retainer.
- Install the master cylinder reservoir to the master cylinder. See MASTER CYLINDER RESERVOIR under REMOVAL & INSTALLATION.
- Install the reservoir cap and diaphragm to the reservoir.
- Install the master cylinder to the vehicle. See MASTER CYLINDER under REMOVAL & INSTALLATION.