Master Cylinder Assembly

ASSEMBLY
1. Clean all parts in clean denatured alcohol. Dry with compressed air.
2. Lubricate new reservoir grommets with brake fluid, then press grommets into master cylinder body. Ensure grommets are properly seated.

Installing Reservoir:

3. Lay reservoir upside down on flat, hard surface. Press master cylinder body onto reservoir using rocking motion.
4. Lubricate new seals with brake fluid and install on secondary piston.
5. Install spring, spring retainer and secondary piston assembly into cylinder.
6. Lubricate seals then install primary piston. Depress primary piston into cylinder, then install lock ring.
7. Install switch piston, failure warning switch, and proportioners, if equipped.

Switch Piston

Switch Piston Assembly:

- Install switch piston into master cylinder body.
- Install O-ring on plug.
- Plug into master cylinder body and torque to 4.5-16 Nm (40-140 in. lb.).
- Install failure warning switch.

Failure Warning Switch

Failure Warning Switch:

- Install new 0-ring on failure warning switch.
- Install switch assembly and torque to 1.7 - 5.6 Nm (15 - 50 in. lb.).
- Install electrical lead.

Proportioner Valve Assemblies

Proportioner Valve Assemblies:

- Install new 0-ring on proportioner valve assemblies.
- Install proportioners into master cylinder body and torque to 24 - 40 Nm (18-30 ft. lb.).
8. Fit diaphragm into reservoir cover, then install cover onto reservoir.
9. Install master cylinder in vehicle. Master Cylinder Installation