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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 770 (General Hydraulic Brake System) >> Repair Instructions >> Master Cylinder Reservoir Replacement >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2002 GMC Safari and 2002 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir.
  2. Clean the reservoir with denatured alcohol, or equivalent.
  3. Dry the reservoir with non-lubricated, filtered air.
  4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
  5. Install the lubricated seals, make sure they are fully seated.
  6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned.
  7. Carefully tap the reservoir retaining pins into place to secure the reservoir.
  8. Install the diaphragm in the cover.
  9. Install the cover on the reservoir.
  10. Remove the master cylinder from the vice.
  11. Install the master cylinder. Refer to Master Cylinder Replacement .
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