Suburban 3/4 Ton 4WD V8-305 5.0L (1986)
7. Remove secondary piston assembly by applying small amount of air pressure to front compensating valve port. Ensure front port is plugged.
8. Remove secondary spring.
CLEANING AND INSPECTION
1. Inspect master cylinder bore for scoring and corrosion. Replace master cylinder if necessary.
CAUTION: Do not hone the cylinder bore. The master cylinder has a hard, highly polished cylinder bore. Honing will destroy this surface which
will cause rapid wear of rubber cups.
2. Clean all metal parts in denatured alcohol or brake parts cleaner.
ASSEMBLY
1. Dip replacement piston assemblies in clean DOT 3 brake fluid for lubrication prior to assembly into cylinder.
2. Install secondary spring.
3. Install secondary piston assembly.
4. Install primary piston return spring and primary piston assembly.
5. Depress primary piston and install snap ring.
6. Install reservoir O-ring and springs.
7. Install valve poppets and compensating valve seals.
NOTICE: Depress and hold the primary piston assembly with a smooth rounded end tool.
8. Install reservoir and reservoir retaining bolts. Tighten reservoir retaining bolts to 18 Nm (13 ft lb).
9. Install diaphragm into the cover.
10. Install master cylinder cover.
