Disassembly and assembly

Master cylinder reservoir

REMOVAL

(1) Remove reservoir cap and empty fluid into drain container.

(2) Clamp cylinder body in vise with brass protective jaws.

(3) Remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove pins (Fig. 40).

Fig. 40 Reservoir Retaining Pins

1 - PIN PUNCH

2 - RESERVOIR

3 - BODY

4 - ROLL PINS

(4) Loosen reservoir from grommets with pry tool (Fig. 41).

Fig. 41 Loosening Reservoir

1 - PRYTOOL

2 - RESERVOIR

3 - GROMMET

4 - MASTER CYLINDER BODY

(5) Remove reservoir by rocking it to one side and pulling free of grommets (Fig. 42).

(6) Remove old grommets from cylinder body (Fig.

43).

Fig. 42 Reservoir Removal

1 - RESERVOIR

2 - GROMMETS

Fig. 43 Grommet Removal

1 - MASTER CYLINDER BODY

2 - GROMMETS

INSTALLATION

CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the grommets using finger pressure only.

(1) Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body (Fig. 44).

Use finger pressure to install and seat grommets.

(2) Start reservoir in grommets. Then rock reservoir back and forth while pressing downward to seat it in grommets.

(3) Install pins that retain reservoir to cylinder body.

(4) Fill and bleed master cylinder on bench before installation in vehicle.

Disc brake caliper

DISASSEMBLY

(1) Drain old brake fluid out of caliper into drain pan.

(2) Remove piston dust boot (Fig. 45). Use screwdriver to push boot out of groove.

Fig. 44 Grommet Installation

1 - WORK NEW GROMMETS INTO PLACE USING FINGER PRESSURE ONLY

Fig. 45 Piston Dust Boot

1 - PISTON BOOT DUST

(3) Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels (Fig. 46).

Towels will prevent piston damage when piston comes out of the caliper bore.

(4) Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper (Fig. 46).

CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out.

WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY.

Fig. 46 Caliper Piston

1 - AIR GUN NOZZLE

2 - FLUID INLET PORT

3 - CALIPER PISTON

4 - PADDING MATERIAL (TO PROTECT PISTON)

5) Remove caliper piston seal with wood pencil or plastic tool (Fig. 47). Do not use metal tools as they will scratch piston bore.

(6) Remove caliper slide pin bushings and boots.

(7) Remove caliper bleed screw and cap.

ASSEMBLY

(1) Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install the boots and bushings in caliper.

(2) Coat caliper piston bore, piston and new piston seal with clean brake fluid.

Fig. 47 Caliper Piston Seal

1 - PISTON SEAL

2 - WOOD PENCIL

(3) Install new piston seal in caliper bore. Press seal into groove with finger (Fig. 48). Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation.

Fig. 48 Caliper Piston Seal

1 - CALIPER PISTON SEAL (PRESS SEAL INTO PLACE WITH FINGER)

(4) Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of piston and dust seal. Grease acts as corrosion protection for these areas.

(5) Slide new seal boot over piston until boot lip seats in piston groove (Fig. 49).

(6) Push retainer part of boot forward until folds in boot snap into place (Fig. 50).

Fig. 49 Sliding Boot Onto Piston

1 - CALIPER PISTON

2 - SLIDE DUST BOOT DOWNWARD OVER PISTON

Fig. 50 Snapping Boot Folds Into Place

1 - FOLD DUST BOOT UPWARD UNTIL IT "SNAPS" INTO PLACE

2 - CALIPER PISTON

(7) Start caliper piston in bore with a twisting motion. When piston is started in seal, push piston only part way into bore (Fig. 51). Maintain uniform pressure on piston to avoid cocking it in bore.

Fig. 51 Installing Caliper Piston And Boot

1 - DUST BOOT

2 - CALIPER PISTON

(8) Press caliper piston to bottom of bore.

(9) Seat piston dust boot with Installer 8248 and Handle C-4171 (Fig. 52).

Fig. 52 Seating Piston Dust Boot

1 - SEAL INSTALLER

2 - DUST BOOT

(10) Install caliper bleed screw and bleed screw cap if removed (Fig. 53).

Fig. 53 Installing Caliper Bleed Screw And Cap

1 - BLEED SCREW CAP

2 - BLEED SCREW

Wheel cylinder

DISASSEMBLY

(1) Remove push rods and boots (Fig. 54).

(2) Press pistons, cups and spring and expander out of cylinder bore.

(3) Remove bleed screw.

Fig. 54 Wheel Cylinder Components-Typical

1 - SPRING

2 - CYLINDER

3 - PISTON CUP

4 - BOOT

5 - PUSH ROD

6 - PISTON

7 - BLEED SCREW

8 - CUP EXPANDERS

ASSEMBLY

(1) Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid.

(2) Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston.

(3) Install spring and expander followed by remaining piston cup and piston.

(4) Install boots on each end of cylinder and insert push rods in boots.

(5) Install cylinder bleed screw.