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Master Cylinder: Replacement

  1. Remove mud and dirt from the surface of brake master cylinder.
  2. Secure the master cylinder in a vise.
    NOTE: To avoid damaging the master cylinder, place between aluminum plates or other material when holding with a vise.
  3. Remove the pin which secures the master cylinder and reservoir tank, then remove the reservoir tank and seal.
    Fig 1: Locating Pin Securing Master Cylinder And Reservoir Tank
    G05662902Courtesy of SUBARU OF AMERICA, INC.
  4. While pushing in the primary piston, remove the C-ring using pliers.
    Fig 2: Removing C-Ring Using Pliers
    G05032791Courtesy of SUBARU OF AMERICA, INC.
  5. While pushing in the primary piston, remove the cylinder pin from the port on the reservoir tank attachment location using a magnet pick-up tool.
    Fig 3: Identifying Cylinder Pin
    G05957187Courtesy of SUBARU OF AMERICA, INC.
  6. Extract the primary piston assembly and secondary piston assembly straight out while taking care not to scratch the inner surface of the cylinder.
  7. Clean the inside of master cylinder with brake fluid. Check the inside of the cylinder for damage, deformation and wear. Replace the master cylinder as an assembly if faulty.
  8. Apply brake fluid to the inner surface of master cylinder and piston assembly.
  9. Make sure that the inner surface of master cylinder and the piston assembly are free of foreign matter. Install the primary piston assembly and the secondary piston assembly to master cylinder, while taking care not to scratch the master cylinder inner surface.
  10. While pushing-in the primary piston, install the cylinder pin.
  11. While pushing-in the primary piston, install the C-ring to the groove using pliers.
    Fig 4: Removing C-Ring Using Pliers
    G05032791Courtesy of SUBARU OF AMERICA, INC.
    CAUTION: Make sure the C-ring is installed to the groove securely.
  12. Install the seal to reservoir tank.
    Fig 5: Identifying Reservoir Tank Seal
    G05957189Courtesy of SUBARU OF AMERICA, INC.
  13. Install the reservoir tank to the master cylinder, and secure with pin.
  14. Replace the O-ring for the master cylinder with a new part.
Fig 6: Identifying Primary Piston And O-Ring
G05957190Courtesy of SUBARU OF AMERICA, INC.
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