REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Disconnect hydraulic lines at master cylinder.
- Remove the retaining nuts and lockwashers that hold cylinder to firewall or the brake booster. Disconnect pushrod at brake pedal (non-power brakes only).
- Remove the master cylinder, gasket and rubber boot.
- On non-power brakes, position master cylinder on firewall, making sure pushrod goes through the rubber boot into the piston. Reconnect pushrod clevis to brake pedal. With power brakes, install the cylinder on the booster.
- Install nuts and lockwashers. Torque nuts to 22-30 ft. lbs. (30-45 Nm).
- Install hydraulic lines then check brake pedal free play.
- Bleed the brakes.
See Figures 4 through 13
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.
- Remove the reservoir cover and diaphragm. Discard any brake fluid in the reservoir.
- Inspect the reservoir cover and diaphragm for cuts, cracks, or deformation. Replace any defective parts.
- Depress the primary piston and remove the lock ring.
- Direct compressed air into the outlet at the blind end of the bore and plug the other outlet to remove primary and secondary piston.
- Remove the spring retainer and seals from the secondary piston.
- Clamp the master cylinder in a vise. Do not clamp it on the master cylinder body. Use a pry bar to remove the reservoir.
- Do not attempt to remove the quick take-up valve from the body. This valve is not serviced separately.
- Remove the reservoir grommets.
- Inspect the master cylinder bore for corrosion. If corroded, replace the master cylinder. Do not use any abrasive on the bore.
- Reassemble, using new seals and grommets. Lubricate all parts with brake fluid.
- Install the reservoir grommets.
- Install the reservoir.
- Install the spring retainer and seals from the secondary piston.
- Install primary and secondary piston.
- Depress the primary piston and install the lock ring.
- Fill with brake fluid. Install the reservoir cover and diaphragm.
- Bleed brake system.