2. Disconnect the reservoir brake fluid supply line adapter from the master cylinder and allow the fluid to drain into a suitable container (see photo 9.2 a and b).
Photo 9.2a. Master cylinder and brake booster.
Photo 9.2b. Brake fluid reservoir tube connections.
3. Disconnect the tube adapters from the master cylinder and cap the open ends of the tubes.
4. Remove the two nuts that secure the master cylinder to the booster surface and remove it from its position. Remove the gasket.
5. Clean off all external dirt.
6. Loosen and remove the locking screw from the master cylinder.
7. From the end of the master cylinder, remove the spring clip, then remove the plastic bushing, washer, gasket, another washer, and the primary piston.
8. Remove the support ring, gasket, another disputable ring, coil spring, stop sleeve and travel limiter screw.
9. Now remove the secondary piston parts. These include gaskets, piston, washer, spacer, backup ring and coil spring.
10. Inspect the piston surfaces and cylinder bore for damage or metal-to-metal contact. If any are evident, replace the entire cylinder.
11. If all components are in good condition, discard the old gaskets and prepare a repair kit that will include all the necessary new gaskets and other parts that require replacement.
12. Use your fingers only to push the gaskets into place. Make sure that the lips of the gasket are facing the correct direction as shown in Figure 9.24.
Figure 9.24. Detailed view of the brake master cylinder (Section 9): 1 - Gasket plug; 2 - Cylinder body; 3 - O-ring; 4 - Brake light switch; 5 - Washer; 6 - Locking screw; 7 - Spring; 8 - Support ring; 9 - Gasket; 10 - Washer; 11 - Secondary piston; 12 - Gasket; 13 - Gasket; 14 - Travel limit screw; 15 - Stopper sleeve; 16 - Spring; 17 - Support ring; 18 - Gasket; 19 - Washer; 20 - Primary piston/lever; 21 - Washer; 22 - Gasket; 23 - Dust cover; 24 - Spring clamp.
13. When inserting components into the cylinder, apply rubber grease to them or dip them in clean brake fluid, and make sure that the gasket lips do not get stuck.
14. Press the primary piston lever while screwing in the lock screw.
15. The rubber plugs of the fluid supply adapters are simply lubricated with brake fluid and inserted into place.
16. Install the brake master cylinder to the brake booster using a new gasket.
17. Completely bleed the brake system (both circuits) as described in Section 12.
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