REMOVAL & INSTALLATION
- Disconnect the negative battery cable.
- Detach the stop light switch wires at the connector.
- Remove the spring retainer and slide the stop light switch off the brake pedal pin just far enough to clear the end of the pin.
- Loosen the master cylinder attaching nuts or bolts from the inside of the engine compartment and slide the master cylinder pushrod, nylon washers, and bushings off the brake pedal pin.
- Remove the brake lines from the master cylinder.
- Remove the master cylinder attaching bolts and remove the master cylinder from the car.
- Insert the pushrod and boot through the dash panel opening, and position the master cylinder on the panel.
- Install the master cylinder retaining bolts or nuts, but do not tighten them.
- Coat the nylon bushings with light engine oil. Install the nylon washer and bushing on the brake pedal pin.
- Position the stop light switch and master cylinder pushrod on the brake pedal pin. Install the nylon bushing and washer, then secure them with the spring retainer.
- Attach the wires at the stop light switch connector.
- Tighten the master cylinder attaching nuts or bolts and connect the brake lines to the master cylinder.
- Fill the master cylinder with new brake fluid.
- Bleed the dual master cylinder and the primary and secondary brake systems.
- Centralize the pressure differential valve.
- Clean the outside of the master cylinder, and remove the cap and rubber gasket. Drain and discard the fluid that is in the master cylinder.
- Remove the secondary piston stop bolt from the bottom of the cylinder.
- Remove the bleeder screw from the cylinder.
- Depress the primary piston and remove the snapring from the groove in the rear of the master cylinder bore.
- Remove the primary piston and pushrod from the master cylinder bore. Do not attempt to service the primary piston in any other way than removing the pushrod from it. The primary piston must be replaced as an assembly.
- Remove the secondary piston from the master cylinder.
Do not disassemble the master cylinder any further than this, as no other parts for the master cylinder are serviced.
- Clean all parts in isopropyl alcohol.
- Thoroughly inspect all parts for wear. If the primary or secondary pistons are defective, they should be replaced as an assembly. Check the master cylinder bore for scoring. The cylinder can be honed to remove surface blemishes, but no more than 0.003 in. can be removed from the cylinder walls. If in doubt, replace the master cylinder.
Before installing any part in the master cylinder, dip it in clean brake fluid.
- Install the secondary piston assembly into the master cylinder.
- Install the primary piston assembly in the master cylinder.
- Install the pushrod, retainer, and boot, depress the piston, and install the snapring.
- Install the secondary piston stop bolt and O-ring in the bottom of the master cylinder.
- Install the bleeder screw.
- Fill the master cylinder with new fluid, depress the pushrod, and open the bleeder to remove most of the air from the master cylinder.