Figure 9.10. Master Cylinder Assembly - Late Models.
1. Remove the master cylinder and clean it.
2. Remove the filter and float from the tank, remove the two gaskets.
3. Remove the stopper cover from the rear of the master cylinder.
4. Remove the primary and secondary piston assemblies, noting the order of removal.
5. On later models (dual-chamber master cylinder with four metal hydraulic clutches), do not attempt to remove the pressure relief valve. It is a sealed part of the master cylinder assembly.
6. When assembling, wet the piston assemblies and the inner surface of the cylinder with clean liquid. All components must be absolutely clean.
7. Referring to Figure 9.11, assemble the secondary piston and return spring and seat them in the master cylinder, then the primary piston with return spring.
Figure 9.11. Correct assembly of the master cylinder piston parts
8. Place the locking cap onto the rear end of the master cylinder, the locking keys should be bent inward into the grooves in the master cylinder body (see figure 9.12).
Figure 9.12. Bend the cover locking tabs in the places shown
9. Place new gaskets on the master cylinder body inlet ports, then place the reservoir on them. Install the float and filter.
10. Install the master cylinder. Check the operation of the brake system.