Disassembly

Compact Master Cylinder Assembly:

1. Remove master cylinder from vehicle. Refer to Brake Master Removal. Compact Master Cylinder
2. Remove reservoir cover (8) and diaphragm (9). Discard old brake fluid from reservoir.
3. Inspect cover (8) and diaphragm (9). Replace if cut, cracked or deformed.

NOTE: Deformed and swollen rubber parts in a brake hydraulic system are indications of improper brake fluid, mineral oil or water contamination. Inspect all rubber parts and clean or replace as necessary. It is recommended that the complete hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed.


4. Remove fluid level sensor (1) and proportioner valve assembly, if equipped (2 through 6).
^ In order to remove the proportioner valve caps (2), it may be necessary to remove the master cylinder reservoir (10).

Removing And Installing Spring Pins:

Installing Reservoir:

MASTER CYLINDER RESERVOIR REMOVAL
1. Clamp flange on master cylinder body (20) in a vise.

NOTE: Do not clamp on master cylinder body (11). Doing so may damage the master cylinder.


2. Remove spring pins (19) by using a suitable 1/8 inch punch to drive them out.
^ Use care not to damage reservoir (10) or cylinder body (11) when driving out spring pins (19).
3. Remove master cylinder reservoir (10) by pulling straight up, away from master cylinder body (11).

Proportioner Valves:

4. Remove reservoir to body "0" rings (7) from grooves in master cylinder reservoir (10) and dispose of "0" rings (7).

PROPORTIONER VALVE REMOVAL
1. Remove proportioner valve caps (2).
2. Remove proportioner valve cap "0" rings (3) and discard.
3. Remove proportioner valve piston springs (4).
4. Remove proportioner valve pistons (5).
^ Use needle nose pliers with care not to scratch or otherwise damage piston stems.
5. Remove proportioner valve seals (6) from proportioner valve pistons (5).

CLEAN
^ All parts in clean, denatured alcohol.
^ Dry with unlubricated compressed air.

INSPECT
^ Proportioner valve pistons (5) for corrosion, or deformation and replace if found.

DISASSEMBLY OF MASTER CYLINDER
1. Depress primary piston (17) while depressing piston retainer (18).
^ Take care not to damage the primary piston, master cylinder bore, or piston retainer groove.
2. Remove primary piston (17), secondary piston (15), secondary piston spring (12), and spring retainer (13).
^ To remove parts, apply low pressure unlubricated compressed air into upper outlet port at blind end of bore with all other outlet ports plugged.
3. Remove secondary seal (16), primary seal (14), and spring retainer (13) from secondary piston (15).

CLEAN
^ All parts in clean, denatured alcohol.
^ Dry with unlubricated compressed air.
^ No abrasives should be used in bore.

INSPECT
^ Master cylinder bore for scoring or corrosion. If noted, replace master cylinder.