Disassembly
To disassemble the brake master cylinder, perform the following operations in sequence.
Fig. 14.16. Master brake cylinder: 1 – tank lock bolt; 2 – brake fluid level sensor; 3 – tank cover assembly; 4 – tank lid; 5 – diaphragm; 6 – filter; 7 – float; 8 – tank; 9 – sealing sleeve; 10 – piston retaining ring; 11 – primary piston assembly; 12 – secondary piston assembly; 13 – main brake cylinder housing; 14 – sealing ring; 15 – piston lock bolt
1. Remove cover 3 (Fig. 14.16) of the tank assembly.
2. Remove cover 4 from the tank.
3. Remove diaphragm 5.
4. Remove filter 6.
5. Remove brake fluid level sensor 2.
6. Remove the float 7.
7. Unscrew the locking bolt 1 of the tank.
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8. Remove the tank 8.
9. Remove the sealing sleeve 9.
Fig. 14.17. Unscrewing the piston lock bolt
10. Loosen the piston lock bolt while simultaneously pressing on the piston (Fig. 14.17).
11. Remove sealing ring 14 (see Fig. 14.16).
Fig. 14.18. Removing the piston retaining ring
12. Remove the piston retaining ring while simultaneously pressing on the piston (Fig. 14.18).
13. Remove the primary piston 11 (see Fig. 14.16) as an assembly.
14. Remove secondary piston 12 as an assembly.
Examination
1. Check the inner surface of the master cylinder housing for corrosion or metal chipping.
2. Check the pistons for signs of corrosion, scoring, wear or damage.
3. Check the diaphragm for cracks or wear.
Assembly
Assembly is carried out in the reverse order of disassembly, taking into account the following.
Fig. 14.19. Places (a) for applying DOT 3 or DOT 4 brake fluid before installing the pistons in the master cylinder: 1 – secondary piston assembly; 2 – primary piston assembly; 3 – main brake cylinder housing
Before installing the pistons into the master cylinder, lubricate them and the cylinder walls with DOT 3 or DOT 4 brake fluid (Fig. 14.19).