HEAVY
DUTY
POWER
BRAKES
5C-5
work
from inside front shell with sharp penknife or
razor
blade to cut off bead of rubber grommet.
Remove check valve and grommet.
DISASSEMBLY
OF
MASTER
CYLINDER
(Fig.
5C-5J
Always
use the correct master cylinder repair kit
when overhauling the master cylinder. Always re-
place all rubber parts. Metal parts cleaner should
NOT
be used on any parts used in the hydraulic
section. Gasoline and kerosene also should never be
used. Rinse all hydraulic parts in clean alcohol and
use emery or crocus cloth to polish them, if nec-
essary. If the bore contains rust, corrosion or pitted
areas,
a master cylinder
hone
may be used; but do
not attempt to re-use a cylinder if the resulting bore
is more than .006" oversize.
1. Pry water and dirt seal and retainer out of
shallow cavity around master cylinder hub.
2.
Press in against rear piston with
round-
end rod
to relieve spring load on piston
stop
screw under
master cylinder bore. Use a
3/8"
wrench to remove
stop
screw and O-ring seal. Maintain pressure on
rear
piston and use
Tru-Arc
pliers to remove snap
ring
from
groove
in master cylinder bore.
3.
Remove rear piston and spring assembly and
discard.
Do NOT attempt to disassemble it since a
complete
new assembly is provided in the repair kit.
4. Remove front piston assembly, front return
spring
and retainer. Slide primary cup and pro-
tector off
nose
of front piston. Use dull scribe to lift
both secondary seals from the
grooves
at the rear
end of the piston. Discard all old rubber parts.
NOTE:
Check valves should not be
replaced
un-
less
one or more of conditions exist as outlined in
Section
5 under Master Cylinder Disassembly.
5.
Install spare
tube
nut in
outlet
ports. Place thin
washer on self-tapping screw and install screw in
tube
seat with washer
bottomed
against
tube
nut.
Hold
screw with screwdriver and use wrench to re-
move
tube
nut, screw, washer and
tube
seat. Remove
rubber
check valve and spring from both
outlet
ports
and
discard both valves and springs.
NOTE:
On master cylinder used with
caliper
disc
brakes, outlet for front wheels does not in-
corporate
a check valve and
spring.
Tube seat
should
only be removed when the tube seat, itself,
is
damaged and requires replacement.
CLEANING
Wash
all hydraulic system parts in alcohol. If
necessary, dip metal parts in a reputable cleaner
to remove rust or corrosive deposits. Polish parts
with emery or crocus cloth immediately and rinse
in
alcohol. Remove
spots,
deposits
or pitted areas
inside the master cylinder bore with emery cloth,
crocus cloth or a hone. Do NOT attempt to re-use
a
cylinder if the resulting bore is more than .006"
oversize. Discard all old rubber parts,
except
filter
diaphragm.
INSPECTION
Inspect all metal parts for damage or excessive
wear.
Replace any damaged or worn parts.
ASSEMBLY
ASSEMBLY
OF
MASTER
CYLINDER
(Fig. 5C-5)
1. Clamp master cylinder in vise with hub end
tilted slightly upward.
2.
Install new secondary seals, back to back, in
grooves
on rear end of front piston. Dip seals in
1.
Snap
Ring
2.
Splash
Shield
Retainer
3.
Splash
Seal
4.
Secondary
Seal
5.
Rear
Piston
and
Spring
Assembly
6.
Primary
Cup
7.
Secondary
Seals
8.
Front
(Floating
Piston)
9.
Protector
10.
Primary
Cup
11.
Retainer
12.
Front
Piston
Return
Spring
13.
Piston
Stop
Screw
and
Seal
14.
Tube
Seats
15.
Check
Valves
16.
Springs
17.
Master
Cylinder
Casting
18.
Hermetic
Diaphragm
19.
Reservoir
Cover
20.
Bale-Type
Retainer
Fig.
5C-5
Master
Cylinder—Exploded
View
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