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Comprehensive Guide to Master Cylinder Service and Brake Systems Maintenance

This guide outlines essential procedures for inspecting and maintaining the master cylinder and brake systems in vehicles. Key steps include checking fluid levels, identifying leaks, and conducting brake pedal tests. It emphasizes the importance of using the correct type of brake fluid (DOT 3, 4, or 5) and highlights potential issues such as trapped air, unequal vehicle loading, and misalignment. Detailed instructions for bleeding the hydraulic system and rebuilding master cylinders are provided, ensuring safe and efficient brake performance.

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Comprehensive Guide to Master Cylinder Service and Brake Systems Maintenance

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  1. MASTER CYLINDER SERVICE CBC AUTOMOTIVE TECHNOLOGY

  2. ROAD TEST FIRST • INSPECT FOR TIRE PROBLEMS • UNEQUAL VEHICLE LOADING • WHEEL MISALIGNMENT • BRAKE SYSTEM ROAD TEST • DRY CLEAN ROADWAY • AVOID CROWNED ROADS • LIGHT AND HEAVY PEDAL PRESSURE • INSPECT BRAKE WARNING LIGHTS

  3. MASTER CYLINDER FLUID LEVELS • FLUID LEVEL WITHIN SPECS • UNEVEN OR LOW LEVEL INDICATE A BRAKE PROBLEM • FILL RESERVOIR • CLEAN CAP • INSPECT DIAGPHRAM • CHECK FLUID APPEARANCE • FILL WITH CORRECT TYPE FLUID

  4. FLUID TYPES • THREE TYPES • DOT 3, 4 AND 5 • LOW FREEZING AND HIGH BOILING POINT • ABSORBS WATER • COMPATIBLE WITH RUBBER AND METALS USED IN BRAKE SYSTEMS

  5. FLUID TYPES • DOT 3 AND 4 • DOT 4 ABSORBS LESS MOISTURE AND HAS HIGHER BOILING POINT THAN DOT 3 • DOT 5 • SILICONE BRAKE FLUID • VERY HIGH BOILING POINT • PURPLE COLORED • DO NOT USE IN ANTI-LOCK SYSTEMS

  6. BRAKE PEDAL TEST FOR FLUID LEAKS • DETERMINE INTERNAL AND EXTERNAL LEAKS • RUN ENGINE • HOLD STEADY BRAKE PEDAL PRESSURE • WATCH FOR LOW PEDAL AND NOISES 56C FIG 3-3 PG 56C

  7. PEDAL TRAVEL TEST • LOW PEDAL • AIR IN HYDRAULIC SYSTEM • LEAKS IN HYDRAULIC SYSTEM • INCORRECT PUSH ROD ADJUSTMENT • MISADJUSTED PARKING BRAKE • WORN BRAKE SHOES • ADJUSTER NOT WORKING • CHECK PEDAL TRAVEL SPECS

  8. MASTER CYLINDER TESTS • TRAPPED AIR • MASTER CYLINDER BYPASS • OPEN REPLENISHING PORTS • SHOULD NOT BE COVERED WHEN BRAKES ARE RELEASED • RESERVE STROKE ON POWER BOOST SYSTEMS

  9. REBUILDING MASTER CYLINDERS • DRAIN MC • DISASSEMBLE • INSPECT • REPLACE ALL RUBBER PARTS • REASSEMBLE • BENCH BLEED BEFORE INSTALLATION 62C FIG 3-11 DO NOT HONE ALUMINUM BORES

  10. BENCH BLEEDING • TWO METHODS • HOSES (66C) • HOOK HOSES TO PORTS • OPERATE PISTONS UNTIL AIR BUBBLES ARE GONE • SYRINGE (69C) • DRAW FLUID OUT PORTS AND INJECT FLUID BACK IN PORTS 66C P5-3

  11. VACUUM BOOSTER PUSHROD LENGTH • MUST NOT BE TOO LONG TO PREVENT BRAKE DRAG • MUST NOT BE TOO SHORT TO CAUSE LOW PEDAL 70C 3-16

  12. FINAL SYSTEM BLEEDING • BLEED MASTER CYLINDER ON VEHICLE (FITTINGS) • ENTIRE HYDRAULIC SYSTEM SHOULD BE BLED • USE CORRECT PROCEDURE • MANUAL BLEEDING • PRESSURE BLEEDING

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