Disassembly (Non-ABS)
- Remove the reservoir from the master cylinder. See MASTER CYLINDER RESERVOIR under REMOVAL & INSTALLATION.
- Remove the master cylinder from the booster. See MASTER CYLINDER under REMOVAL & INSTALLATION.
- Remove the piston stopper snap ring from the master cylinder. Remove the piston stopper. Remove the cylinder cup. Remove the plate.
- Pull the primary piston assembly and the O-ring carefully from the master cylinder in order to prevent damage to the inside of the master cylinder wall. Remove the secondary piston stopper bolt and the washer from the master cylinder. See Fig 1 .
- Remove the secondary piston assembly by blowing compressed air into the secondary piston stopper bolt hole. Remove the piston cup and the secondary piston pressure cup. Remove the spring. Inspect the components for wear or damage. Replace the components if necessary. See Fig 1 .
- Wash disassembled parts with brake fluid. Inspect the master cylinder bore for scoring or corrosion. Replace a damaged master cylinder.
- Rinse the cylinder in clean brake fluid. Shake excess rinsing fluid from the cylinder.
CAUTION:
DO NOT place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.
NOTE:
DO NOT use a cloth in order to dry the cylinder, because lint from a cloth will stick to the cylinder bore surfaces.