Chevrolet Citation/Omega/Phoenix/Skylark 1980-1985 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION





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Fig. Fig. 1 On vehicles that do not have power brakes, the master cylinder is mounted to the firewall



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Fig. Fig. 2 The master cylinder is mounted to the power brake booster, on vehicles equipped with power brakes



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Fig. Fig. 3 To remove the master cylinder, use a clean syringe to remove the brake fluid



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Fig. Fig. 4 Unplug the electrical connector from the master cylinder



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Fig. Fig. 5 With a shop rag placed under the lines, use a flare nut wrench to loosen ...



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Fig. Fig. 6 ... then remove the brake fluid lines from the master cylinder



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Fig. Fig. 7 Unfasten the master cylinder-to-vacuum booster retaining nuts ...



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Fig. Fig. 8 ... then remove the brake master cylinder from the vacuum booster

  1. If your car does not have power brakes, disconnect the master cylinder pushrod at the brake pedal inside the car. The pushrod is retained to the brake pedal by a clip; there is a washer under the clip, and a spring washer on the other side of the pushrod.
  2.  
  3. Use a clean syringe to remove as much of the fluid from the master cylinder as possible.
  4.  
  5. Unplug the electrical connector from the master cylinder.
  6.  
  7. Place a number of cloths or a container under the master cylinder to catch the brake fluid. Disconnect the brake tubes from the master cylinder; use a flare nut wrench if one is available. Tape over the open ends of the tubes.
  8.  

Brake fluid eats paint. Wipe up any spilled fluid immediately, then flush the area with clear water.

  1. Remove the two nuts attaching the master cylinder to the booster or firewall.
  2.  
  3. Remove the master cylinder.
  4.  

To install:

  1. Attach the master cylinder to the firewall or the booster with the nuts. Torque to 22-30 ft. lbs. (30-45 Nm).
  2.  
  3. Reconnect the pushrod to the brake pedal with non-power brakes.
  4.  
  5. Remove the tape from the lines and connect to the master cylinder. Torque to 10-15 ft. lbs. (13-20 Nm). Connect the electrical lead.
  6.  
  7. Bleed the brakes.
  8.  

OVERHAUL





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Fig. Fig. 9 Exploded view of the master cylinder assembly



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Fig. Fig. 10 Use a large prybar to carefully separate the reservoir from the master cylinder



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Fig. Fig. 11 Install the master cylinder body to the reservoir using a rocking motion

This is a tedious, time-consuming job. You can save yourself a lot of trouble by buying a rebuilt master cylinder from your dealer or parts supply house. The small difference in price between a rebuilding kit and a rebuilt part usually makes it more economical, in terms of time and work, to buy the rebuilt part.

  1. Remove the master cylinder.
  2.  
  3. Remove the reservoir cover and drain the fluid.
  4.  
  5. Remove the pushrod and rubber boot on non-power models.
  6.  
  7. Unbolt the proportioners and failure warning switch from the side of the master cylinder body. Discard the O-rings found under the proportioners. Use new ones on installation. There may or may not be an O-ring under the original equipment failure warning switch. If there is, discard it. In either case, use an O-ring upon assembly.
  8.  
  9. Clamp the master cylinder body in a vise, taking care not to crush it. Depress the primary piston with a wooden dowel and remove the lock ring with a pair of snapring pliers.
  10.  
  11. The primary and secondary pistons can