Disassembly and Assembly
1991
06-06-12 Hydraulic Brake System 06-06-12
DISASSEMBLY AND ASSEMBLY
Master Cylinder (Except ABS)
Disassembly
1. Using a Rotunda Digital Volt-Ohmmeter 007-00001 or equivalent, check continuity of the reservoir. When the reservoir is full, the switch should be open.
2. Using a screwdriver, push down on the low fluid level sensor float. Use a volt-ohmmeter to check continuity of the switch. The switch contacts should be closed when the float is pushed down.
3. If the low fluid level switch is defective, replace it.
4. Mount the master cylinder in a soft jawed vise and 1, remove the reservoir retaining screw.
5. Gently pry up on the reservoir with a small pry bar and remove it from the master cylinder.
1991
06-06-13 Hydraulic Brake System 06-06-13
DISASSEMBLY AND ASSEMBLY (Continued)
6. Push in on the primary piston and remove the secondary piston stop bolt.
7. Using snap ring pliers, remove the master cylinder snap ring.
Assembly
8. Use a small amount of compressed air to push out the master cylinder pistons. Be careful to catch the pistons in a cardboard box filled with clean shop towels to prevent damage to the pistons. Use only the minimum amount of air pressure needed to drive out the pistons.
9. Remove the reservoir grommets from the master cylinder.
1. Clean the master cylinder housing with denatured
alcohol. Be sure no residue remains.
2. Lubricate the bore with the special assembly lubricant supplied in the rebuilding kit or with clean DOT-3 brake fluid.
3. Clean the master cylinder pistons with denatured alcohol and install new seals. Some kits may come with new master cylinder pistons.
NOTE: Lubricate seals with clean DOT-3 brake fluid.
1991
06-06-14 Hydraulic Brake System 06-06-14
DISASSEMBLY AND ASSEMBLY (Continued)
4. Lubricate the seals on the master cylinder pistons with clean brake fluid and install the pistons in the master cylinder housing.
5. Install the snap ring.
6. Push in on the primary piston and install the secondary piston stop bolt.
7. Install the reservoir grommets in the master cylinder housing and lubricate them with clean brake fluid.
8. Place the reservoir upside down on a clean work bench and press the master cylinder down over the reservoir.
9. Install the reservoir retainer screw.
Master Cylinder (With ABS)
Disassembly
1. Remove the fluid level sensor.
2. Remove the reservoir attaching screw.
3. Remove the reservoir assembly.
4. Remove the bushings.
5. Remove the stop pin and 0-ring.
6. Push the piston in fully with a rod and remove the snap ring using snap ring pliers.
7. Remove the spacer.
8. Remove the piston guide assembly.
9. Remove the stopper.
10. Remove the primary piston assembly.
CAUTION: Use a rag to catch the secondary piston assembly when applying compressed air.
11. Remove the secondary piston assembly by gradually blowing compressed air into the cylinder port.
12. Remove the O-ring.
1991
06-06-15 Hydraulic Brake System 06-06-15
DISASSEMBLY AND ASSEMBLY (Continued)
Assembly
1. Lubricate a new 0-ring with the specified brake fluid. Install the 0-ring.
2. Lubricate the seals on the secondary piston assembly. Install the secondary piston assembly with the piston hole facing the stop pin.
3. Install and tighten the stop pin and a new O-ring.
4. Push and release the piston to verify that it is held by the stop pin.
1991
06-06-16 Hydraulic Brake System 06-06-16
DISASSEMBLY AND ASSEMBLY (Continued)
5. Lubricate the stopper and the piston guide assembly with the specified brake fluid. Slowly and evenly insert the primary piston assembly, stopper, and piston guide assembly into the cylinder.
NOTE: If the piston guide assembly is not easily installed, use a suitable pipe or socket and tap it into position.
6. Install the spacer.
7. Install the snap ring.
8. Lubricate the bushings with the specified brake fluid. Install the bushings.
9. Install the reservoir assembly.
10. Install the reservoir attaching screw.
11. Install the fluid level sensor.