1. After removing the unit from the machine, clean off any external dirt.
2. Remove the fluid reservoir from the cylinder body.
3. Remove the snap ring from the end of the cylinder case. To do this, lightly press the primary piston using a rod to relieve the tension on the spring ring.
4. Remove the primary piston, paying attention to how the seals are installed.
5. Insert the rod and push the secondary piston so that the set screw can be removed from the cylinder body (Pic. 9.33).
Pic. 9.33 — Pressure on the secondary piston of the main cylinder (AND THOSE)
6. Remove the secondary piston by tapping the end of the cylinder against a block of wood. Pay attention to how the seals are installed.
7. Inspect the piston surfaces and cylinder barrel for rust, scratches, or metal-to-metal friction areas. If this is the case, replace the entire master cylinder.
8. If the components are in good condition, clean them in hydraulic fluid or methyl alcohol - and nothing else.
9. Obtain a repair kit that contains all the necessary spare parts.
Procedures for working with the kit "free" oil seals.
10. Install new seals on the pistons, pushing them into place only with your fingers. It is important that the new seals are installed in the same way as the old ones; They are cone-shaped and will only function correctly if installed in the correct order.
11. Assembly is carried out in reverse order. Be as careful as possible as the pistons enter the cylinder bores so as not to cut off the seal lips. Before assembly, soak each component in clean hydraulic fluid. Always install a new circlip from the repair kit.
12. Install new rubber sealing rings and place the fluid reservoir in its place on the cylinder body.
13. Pour some clean fluid into the reservoir and prepare the master cylinder for operation before installation by pressing the primary piston several times with a rod. Naturally, a large amount of liquid will be ejected from the open ports of the cylinder.
Procedures for working with a pre-assembled kit.
14. Lubricate the cylinder with brake fluid.
15. Clamp the cylinder in a soft jaw vice so that the barrel is more or less horizontal. Lightly tighten the locking screw, but not so far that it protrudes into the barrel.
16. Remove the large plug from the tube. Remove all components from the short part of the tube and push the short part into the long part so that they are butt up.
17. Insert the tube into the cylinder barrel up to the collar on the short cuff. Using a blunt rod, push the secondary piston into the barrel until it reaches the end of the cylinder. Tighten the locking screw, remove the rod and collar, and fully tighten the locking screw.
18. Change the position of the master cylinder in the vise so that the bore of the barrel faces up.
19. Lubricate the primary piston skirt and seal grooves with the special lubricant provided in the repair kit. Install the retaining gasket onto the piston.
20. Adjust the tube so that the end of the long part is flush with the inner collar of the short part.
21. Install the front oil seal onto the primary piston with the open end of the oil seal facing the front of the master cylinder. Place the tube over the cylinder to compress the seal, insert the piston and tube into the barrel some distance and remove the tube.
22. Place the middle ring on the piston, then install the other oil seal using the tube in the same way.
23. Place the end gasket on the primary piston, then lightly press the piston and install the snap ring. Make sure that the snap ring is in place and that the piston can move freely.
24. Install new seal rings and replace the fluid reservoir.
25. Prepare the cylinder for operation by pouring clean brake fluid into the reservoir and pressing the pistons with a rod so that fluid flows out of all holes.
Pic. 9.30 — Removing the reservoir from the ATE type main cylinder
Pic. 9.31 — Main cylinder type ATE disassembled
Pic. 9.32 — Removing the primary piston of the main cylinder (AND THOSE)
Pic. 9.34 — Removing the secondary piston (AND THOSE)
Pic. 9.35 - Using a tube to install the primary piston assembly (AND THOSE)
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