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Master Cylinder: Disassembly

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the 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.
  5. Inspect the reservoir cap and diaphragm for cuts, 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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