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Master Cylinder: Reassembly

  1. Position master cylinder in a vise with outlet ports facing up. Insert check valve spring in residual check valve, and position assembly in outlet port.
    CAUTION: Install residual check valve(s) in only those outlets which feed drum brakes. Be sure spring is properly seated in bottom of port.

    Place new brass tubing seat(s) into port(s) and thread spare brake line tubing nut into port until seat is bottomed in port. Remove nut.

  2. Remove cylinder from vise, and clean housing. Dip all parts, except cylinder housing, in clean brake fluid prior to final assembly. Install two secondary cups, back-to-back, on secondary piston, then assemble cup protector, primary cup, spring retainer, and secondary piston return spring on opposite end of piston. Insert secondary piston assembly into bore in cylinder.
  3. Install new "O" ring on piston stop, and start stop into cylinder body. On vehicles equipped with standard brakes, position boot, snap ring, and push rod retainer on push rod, and seat assembly in primary piston. Install primary piston in cylinder bore, tighten secondary piston stop screw and install snap ring in end of cylinder bore.
  4. On vehicles equipped with power assisted brakes, position stop plate and snap ring on primary piston, and install assembly in bore of master cylinder.
  5. Before installing master cylinder assembly on vehicle, bleed as follows: Support master cylinder in a vise and fill both fluid reservoirs. Loosely install plugs in both outlet ports, then depress primary piston several times until air bubbles cease to appear in fluid reservoirs. Tighten plugs and attempt to depress piston. Piston travel will be greatly restricted when all air is expelled. Remove plugs, install cover and diaphragm, and remove assembly from vise.