Master Cylinder Assembly Overhaul

Disassembly





1. [For vehicle not equipped with ABS] Remove piston stopper bolt (1).





2. [For vehicle equipped with ABS] Push in primary piston (1) to remove secondary piston stopper pin (2) from master cylinder as shown.
3. Remove circlip (1).





4. Remove primary piston. Then remove secondary piston by blowing compressed air (2) into hole. Be cautious during removal as secondary piston jumps out.

Reassembly

CAUTION:
^ Never use any mineral oil such as kerosene oil and gasoline when washing and assembling parts.
^ Check inside of cylinder wall, pistons and cup seals are free from any foreign objects such as dust and dirt and use case not to cause any damage with a tool during assembly.
^ Do not drop parts. Do not use any part which has been dropped.

1. Apply brake fluid to inside of cylinder and contact surface of piston assembly (new piston cups, new cylinder cup).





2. Install secondary return spring and secondary piston (1) into cylinder body (4).

NOTE: For vehicles equipped with ABS, align oblong hole in secondary piston (2) with stopper pin hole (3) in master cylinder body (4) when installing it.

3. Install primary piston assembly into cylinder body.





4. Install piston stopper bolt (1) or stopper pin (2) with pistons pushed in all the way and tighten or install it.
Tightening torque
Piston stopper bolt (a): 10 Nm (1.0 kgf-m, 7.5 ft. lbs.)





5. Install circlip (1).