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5 - 1 2
BRAKES
•
(7) Remove the secondary p i s t o n w i t h compressed
a i r applied t h r o u g h t h e b r a k e l i n e port o r t h e com-
pensator port a t the b o t t o m o f t h e reservoir. Discard
t h e piston assembly after removal.
COVER
COVER
CLAMP
RF495
Fig. 5 Removing/Installing Cylinder Cover
Fig. 6 Integral Cylinder Components
Cylinder Cleaning And Inspection
Clean the cylinder body and cover w i t h b r a k e f l u i d
or brake cleaner only. Do not use any other type of
solvents, or cleaning agent.
Inspect the cylinder body and bore. L i g h t discolor-
a t i o n of the cylinder bore is n o r m a l and is a n accept-
able condition. The bore should be smooth and free of
scores, scratches, corrosion and rust. Replace t h e cyl-
inder i f the bore is w o r n , scored, or corroded. D o n o t
h o n e t h e b o r e i n a n a t t e m p t t o restore t h e surface
f i n i s h . Replace the cylinder i f t h e bore is damaged i n
any way. Also replace t h e cylinder i f t h e body is
cracked, porous, or t h e compensator ports a t t h e bot-
t o m of each reservoir is blocked or damaged.
Inspect the cover a n d gasket. Replace t h e gasket i f
distorted, cut, or t o r n . Replace the cover a n d r e t a i n -
i n g w i r e i f either component is distorted or damaged
i n any way.
Do n o t reuse t h e o l d piston assemblies. Discard
these parts as soon as t h e y are removed. I n s t a l l r e -
placement p r i m a r y and secondary p i s t o n assemblies
only.
INTEGRAL
CYLINDER
ASSEMBLY
(1) Coat t h e cylinder bore a n d replacement piston
assemblies w i t h a l i b e r a l q u a n t i t y o f clean brake
f l u i d .
(2) I n s t a l l t h e secondary p i s t o n assembly i n t h e
bore w i t h a t u r n i n g m o t i o n . Do n o t use m e t a l tools o f
any k i n d t o help ease t h e p i s t o n i n t o place. Sharp
edge tools w i l l scratch t h e bore a n d c u t t h e piston.
(3) I f the c y l i n d e r i s equipped w i t h a stop screw for
the secondary piston, press t h e p i s t o n t o t h e b o t t o m
of the bore a n d i n s t a l l t h e screw.
(4) I n s t a l l t h e p r i m a r y piston i n t h e bore.
(5) Press t h e pistons i n w a r d w i t h a wood dowel and
i n s t a l l the piston snap r i n g . Be sure t h e snap r i n g is
f u l l y seated.
(6) I n s t a l l a new gasket on t h e cover i f necessary.
(7) I n s t a l l t h e cover r e t a i n i n g w i r e on the cylinder
i f removed.
(8) F i l l a n d bleed t h e master c y l i n d e r on the bench
and before i n s t a l l a t i o n o n t h e vehicle. Refer t o t h e
procedure i n t h i s section.
MASTER CYLINDER BLEEDING
Master cylinder bleeding should be performed on
the bench before i n s t a l l a t i o n i n t h e vehicle. For the
i n t e g r a l master cylinder, r e q u i r e d bleeding tools i n -
clude fabricated bleed tubes a n d a wood dowel. F o r
the two-section master cylinder, r e q u i r e d bleeding
tools include bleed tubes C-4029 a n d a wood dowel
(Fig. 7).
CYLINDER
BLEEDING
PROCEDURE
(1) M o u n t the master cylinder assembly i n a vise.
(2) A t t a c h t h e bleed tubes t o t h e cylinder outlet
ports and i n s e r t t h e tubes i n the reservoir f l u i d com-
partments (Fig. 7).
(3) F i l l t h e reservoir w i t h fresh brake f l u i d .
(4) Press t h e cylinder pistons i n w a r d w i t h a wood
dowel. T h e n release t h e pistons a n d allow t h e m to re-
t u r n under s p r i n g pressure. Continue bleeding oper-
ations u n t i l a i r bubbles are no longer visible i n the
f l u i d .
MASTER CYLINDER INSTALLATION
(1) Bleed master cylinder on bench before i n s t a l l a -
t i o n .
(2) Position master cylinder o n studs o f power
brake u n i t .
(3) A l i g n power brake push r o d w i t h master c y l i n -
der piston.
(4) I n s t a l l and t i g h t e n cylinder a t t a c h i n g nuts to
23 N*m (200 in-lbs).
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