Honda Accord/Civic/Prelude 1973-1983 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



See Figure 1

Before removing the master cylinder, cover the body surfaces with fender covers and rags to prevent damage to painted surfaces by brake fluid.

  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Remove the master cylinder-to-vacuum booster attaching bolts and the master cylinder from the vehicle.
  4.  
  5. To install, reverse the removal procedures. Bleed the brake system.
  6.  



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Fig. Fig. 1: Removing the master cylinder assembly

OVERHAUL



See Figures 2 through 10

  1. Remove the fluid reservoir caps and floats, then, drain the reservoirs.
  2.  
  3. Loosen the retaining clamps and remove the reservoirs.
  4.  
  5. Remove the primary piston stop bolt.
  6.  
  7. Remove the piston retaining clip, washer and the primary piston.
  8.  
  9. Wrap a rag around the end of the master cylinder, so that it blocks the bore. Hold your finger over the stop bolt hole and direct a small amount of compressed air into the primary outlet. This should slide the primary piston to the end of the master cylinder bore, so it can be removed.
  10.  
  11. Remove the two union caps, washers, check valves and springs.
  12.  
  13. For overhaul procedures, check the following:
    1. Clogged orifices in the pistons and cylinder.
    2.  
    3. Damage to the reservoir attaching surface.
    4.  
    5. Damage to the check valves.
    6.  
    7. Wear or damage to the piston cups.
    8.  
    9. The clearance between the master cylinder bore and the pistons. The clearance should be 0.020-0.127mm.
    10.  

  14.  
  15. To assemble of the master cylinder, reverse the disassembly procedures. Be sure to check the following:
    1. The check valves and piston cups should be replaced when the master cylinder is assembled, regardless of their condition.
    2.  
    3. Apply a thin coat of brake fluid to the pistons before installing. When installing the pistons, push in while rotating to prevent damage to the piston cups.
    4.  
    5. Tighten the union cap and stop bolts securely.
    6.  

  16.  



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Fig. Fig. 2: Exploded view of the master cylinder-1982 Civic



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Fig. Fig. 3: View of the master cylinder assembly in vise



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Fig. Fig. 4: Removing the outer retaining snapring of the master cylinder



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Fig. Fig. 5: Removing the washer of the master cylinder



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Fig. Fig. 6: Removing the spacer of the master cylinder



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Fig. Fig. 7: Removing the piston retaining bolt of the master cylinder



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Fig. Fig. 8: Removing the piston assembly of the master cylinder



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Fig. Fig. 9: Removing the piston assembly of the master cylinder



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Fig. Fig. 10: Exploded view of the master cylinder assembly and necessary tools

 
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