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Disassembly

016

Remove the master cylinder from the vehicle; "2 nuts and 2 brake lines".

001

Remove the two clips that secure the cover.

002

Two clips folded back and cover removed.

003

Empty master cylinder. Clean out old “gunk” from inside.

018

Some masters have a small screw on the bottom, Bendix; remove it as shown by the arrow. 

004

Locate the clip at the back of the master cylinder.

005

Locate the clip at the back of the master cylinder.  You may need to depress the piston, it is under light spring pressure.

006

Clip removed - piston comes out.

007

Remove primary piston.

008

 Remove secondary piston, by”tapping “on block of wood or applying a small amount of air pressure to front port hole, where the brake line was.

009

 Secondary piston partially out of bore; remove it.

010

Secondary piston removed from bore.  

011

Inspect the bore, for scratches, pitting, rust, etc. 

012

 Inspect the master cylinder interior.

013

Parts after removal.

021

You can inspect the old parts, for pitting,or damaged seals, this one had pitted piston.

022

Pitted piston 

023

 Pitted piston 


Reassembly

Re-assembly is done in reverse order; install the secondary piston, the primary piston, and then the circular clip.

The re-assembly process will be much easier if you soak the parts in clean brake fluid prior to reassembling the unit.

Make sure all parts and the bore are very clean.

Bleed master cylinder on the bench.

The entire rebuild including removal from vehicle, disassembly, rebuilding, bleeding and re-installing took about one hour.

014

016

017

018

019

Kit used ordered from Wilcox.

020

Kit # 28978. Cost about $25

024

Tools used in this rebuild.

025

Rebuilt, cleaned and as good as new! 

 
Byrne.jpg

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