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Master Cylinder: Disassembly

WARNING: This page does not describe the selected car, but rather 12 other vehicles, including the 2003 GMC Yukon XL, 2003 GMC Yukon, 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, and 2003 Chevrolet Tahoe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the brake master cylinder from the vehicle. See MASTER CYLINDER  under REMOVAL & INSTALLATION.
  2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible.
  3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
  4. Remove the reservoir cap and diaphragm from the reservoir. See Figure.
  5. Inspect the reservoir cap and diaphragm for cuts or cracks, nicks or deformation. If any of these conditions are present, replace the affected components.
  6. Remove the master cylinder reservoir from the master cylinder. See MASTER CYLINDER RESERVOIR  under REMOVAL & INSTALLATION.
  7. Using a smooth, round-ended tool, depress the primary piston and remove the piston retainer.
  8. Remove the primary piston assembly from the cylinder bore.
  9. 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.
  10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston.
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