Dodge RAM TRUCK 1500 1995 Service Manual page 185

B R MASTER CYLINDER 5-13
(9) Remove secondary piston spring (Fig. 12). Tilt
cylinder body downward so spring will slide out of
bore.
CYLINDER
BODY
J9405-10
Fig. 12 Master Cylinder Piston Removal
(10) Disassemble secondary piston. Remove seal
retainer from piston. Then remove front and rear
seals from piston (Fig. 13). Discard seals, spring, and
retainer after removal. These parts are not reusable.
SPRING
PISTON J9405-11
Fig. 13 Secondary Piston Components
11STER CYLINDER CLEANING AND INSPECTION
Clean the cylinder body and reservoir with Mopar
brake cleaner only. Do not use any other type of
cleaning solvent. Dry the cylinder parts with com­
pressed air. The reservoir can be air dried or wiped
dry with lint-free shop towels.
Inspect the cylinder bore. A light discoloration of
the bore surface is normal and acceptable. However,
replace the cylinder body if the bore is scored, pitted,
or corroded.
Inspect the cylinder cover and diaphragm seal. Re­
place the seal if torn, or distorted. Replace the cover
if warped, cracked, or the snap fasteners are dam­
aged.
Inspect the reservoir. A slight discoloration of the
reservoir surface is normal. Replace the reservoir if
distorted, cracked, or otherwise damaged.
Inspect the take up valve in the cylinder body. The
valve should move freely and not be stuck or seized.
The valve is not serviceable. It will be necessary to
replace the cylinder body if the valve is faulty.
Inspect condition of the secondary piston. Replace
the piston if it is scored, corroded, or doubt exists
about its condition.
MASTER CYLINDER REASSEMBLY
(1) Coat cylinder body bore, piston components and
reservoir grommets with fresh, clean brake fluid.
(2) Mount cylinder body in vise. Clamp one cylin­
der mounting ear in vise jaws.
(3) Assemble secondary piston * components (Fig.
13). Be careful when installing seals. Avoid distorting
them during installation.
CAUTION: Do not use any kind of metal tool to ease
piston seal installation in the cylinder bore. Metal
tools will cut the seals and scratch the bore. If a
tool is needed, use a small flexible item made from
nylon, rubber or plastic only.
(4) Install secondary piston assembly (spring end
first), in cylinder bore. Do not force piston into
bore. Work it into place with a twisting/turning
motion.
(5) Install primary piston in cylinder bore (spring
end first). Do not force piston into bore. Work it
into place with a twisting/turning motion.
(6) Insert piston retaining snap ring in cylinder
body. Then push pistons inward with wood dowel and
seat snap ring.
CAUTION: B e very sure the piston retaining snap
ring is fully seated. Recheck snap ring installation
before proceeding.
(7) Install new grommets on cylinder body (Fig.
14).
(8) Remove cylinder body from vise.
(9) Position reservoir on clean work surface with
fluid inlet necks facing upward (Fig. 14). Padding
work surface with clean shop towels will keep reser­
voir in place during installation. It will also keep dirt
out as well.