Honda Civic/CRX/del Sol 1984-1995 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



See Figures 1 through 7



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Fig. Fig. 1: Unplug the fluid sensor lead-1984-87 shown



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Fig. Fig. 2: Disconnect the brake lines using the correct wrench. Plug the brake lines as soon as you remove them



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Fig. Fig. 3: Unbolt the master cylinder from the power brake booster



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Fig. Fig. 4: The master cylinder comes free after unbolting it from the brake booster. Notice the spilled fluid on the edge of the catch tray



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Fig. Fig. 5: This catch tray prevents fluid from spilling and comes in handy when refilling the reservoir. It simply unclips

Before removing the master cylinder, cover the body surfaces with fender covers and shop towels or plastic sheeting to prevent damage to painted surfaces by brake fluid. If any fluid does contact painted or anodized surfaces, wipe the fluid off immediately.

The brake fluid in the reservoir may be sucked out with a clean turkey baster or other similar device prior to removing the brake lines.

  1. Disconnect the fluid sensor lead.
  2.  
  3. Disconnect and plug the brake lines from the master cylinder.
  4.  
  5. Remove the master cylinder-to-vacuum booster attaching bolts and the master cylinder from the vehicle.
  6.  
  7. Install the master cylinder to the booster and tighten the mounting nuts to 11 ft. lbs. (15 Nm).
  8.  
  9. Connect the brake lines to the master cylinder. Tighten them to 14 ft. lbs. (19 Nm).
  10.  

Be sure to use a line wrench when connecting the brake lines. Standard open end wrenches may slip and round over the fittings. Never use any other lubricant for brake line fittings than clean brake fluid.



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Fig. Fig. 6: Master cylinder, brake booster and dual proportioning valve mounting



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Fig. Fig. 7: Exploded view of the master cylinder-1984-87 model shown

OVERHAUL



1984-87 Models

See Figures 8 through 18

Before beginning this procedure, make sure you have available a master cylinder rebuild kit, or the necessary internal replacement parts to repair what you take apart. If you are unable to obtain the parts needed, you may have to forego the following procedure and replace the faulty master cylinder with a new one.



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Fig. Fig. 8: Remove the snapring from the secondary piston assembly-1984-87 models only



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Fig. Fig. 9: Remove the outer secondary cup from the master cylinder



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Fig. Fig. 10: Remove the stop bolt



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Fig. Fig. 11: Pry out the inner secondary cup



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Fig. Fig. 12: The snapring pliers are used again to remove the inner snapring



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Fig. Fig. 13: Remove secondary piston A and B assembly



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Fig. Fig. 14: Remove the primary piston



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Fig. Fig. 15: The secondary and primary piston assemblies and related clips, washers and cups-1984-87 models



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Fig. Fig. 16: Remove the screw to the secondary spring in order to disassemble piston B and piston A and the rest of the assembly

  1. Remove the master cylinder from the vehicle and mount it securely on a bench vise being cautious not to clamp it too hard.
  2.  
  3. Remove the reservoir cap, fluid level sensor, filter and seal.
  4.  
  5. Remove the outer snapring from the secondary piston assembly. Remove the washer secondary cup and secondary piston bushing.
  6.  
  7. Remove the stop bolt, and remove the inner snapring while pushing on the secondary piston assembly.
  8.  
  9. Remove the primary piston assembly from the bore.
  10.  
  11. Remove the screw from the secondary piston and remove the spring.
  12.  

To Install:
  1. Clean all parts thoroughly, with clean brake fluid.
  2.  

Use only clean brake fluid to clean master cylinder components. Other solvents may damage the components.



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Fig. Fig. 17: Assembling the master cylinder pistons



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Fig. Fig. 18: Install the master cylinder cups and seals during reassembly

  1. Lubricate new piston assemblies with brake fluid then install them in the master cylinder body.
  2.  
  3. Press down on the piston assembly and install the stop bolt in the master cylinder body. Tighten the stop bolt to 7 ft. lbs. (10 Nm).
  4.  
  5. Again press down on the piston assembly and install the inner snapring.
  6.  
  7. Install the secondary cups, bushing and outer snapring.
  8.  
  9. Insert a new seal on the master cylinder mounting flange and install the master cylinder in the vehicle. Bleed the brake system when finished.
  10.  

1988-95 Models

The Honda Motor Co. does not recommend disassembly of the master cylinder assembly for 1988-95 models. If a master cylinder for a 1988-95 Civic is found to be faulty, replace the unit with a new one.

 
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