Master Cylinder: Reassembly

Lubricate all parts with clean brake fluid, reverse disassembly procedure, and note the following: Install seal on primary piston with groove facing forward. Install valve seal with smallest diameter leading onto valve head.

1. Disassembly (XKE - 1)  Remove bolts, fittings, and valve trap assembly from top of cylinder. Remove dust boot, compress piston return spring and remove spring retainer. Press piston into bore, remove snap ring using special snap ring pliers (7066), and remove piston assembly, spring, spring retainer and lever.
   NOTE: Bearing "O" ring seal may expand into snap ring groove making removal difficult. If necessary, wrap jaws of pliers with tape and use to extract piston assembly.
   Fig 1: Master Cylinder Assembly (XJ6 & XJ12)

   Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
   Fig 2: Master Cylinder & Reaction Valve (XKE)

   Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
2. Remove bearing, "O" ring seal, and secondary cup assembly from piston. Remove plastic spring retainer.
   NOTE: Retainer is a press fit on piston and requires firm force against its back to remove.

   Remove main cup and piston washer. Remove reaction valve assembly from cylinder body. Remove valve piston by inserting a screwdriver into fluid line outlet port. Move valve along its bore until it can be removed by hand. Remove "O" ring and seal from piston.

Coat all parts with clean brake fluid, reverse disassembly procedure, and note the following: When installing piston lever, make sure lever tab drops into recess when lever reaches bottom of cylinder bore. If necessary, press reaction valve piston forward with a blunt screwdriver fed through fluid outlet port.