Front Master Cylinder

[Guest]

Ok, I am rebuilding my brakes and have finished rebuilding the rear master cylinder and caliper so they are good.

I have also finished rebuilding both my front calpiers but I am stuck on the front master cylinder. I have taken the clip out and the washer but the rest will not come out. I have sprayed PB blaster and let it sit for a few days but still nothing. I can compress the spring and let it pop out but it still won't come out.

I tried to do a search but for some reason it's not working so I went through the treads looking for something and found this, http://www.thegsresources.com/_forum...inder+assembly

but it only shows how to put it back in. Am I missing anything? Should I try to pull the piece out with pliers? I don't want to mess anything up and have to buy another MC.





Little help please!

[Nessism]

I believe corrosion is holding in the seal retainer. Your only real choice is heating the body a little, PB Blaster, and grabbing the plunger with some pliers and pulling. I've had to do this before and while the plunger got damaged, it needed to be replaced anyway. If you push in the plunger first, then pull back quickly you can shock the seal to pull loose.

When you go to replace the plunger, OEM Suzuki parts are vastly superior to aftermarket like K&L.

Good luck

[1_v8_merc]

Drill a drywall screw or something down into the plunger, then yank it out with pliers.

Sometimes these plungers can become corroded beyond belief...heat and soaking do not always work.

[Tech73]

It's a little to late for buying OEM Suzuki brake parts for the rear. I had already bought K&L stuff for the rear but I did buy factory for the front master cylinder.

I will do what you suggest first Nessism and if that doesn't work I'll try the drywall screw but I hope I won't have to do that.

Thanks for the advice guys.

[2BRacing]

Place a block of wood on your workbench and tap the M/C downwards with short, sharp taps onto the wood, with the open end of the piston downwards towards the wood. Maybe this will make the piston come out.

Alternatively, stuff a piece of rag into the fluid reservoir and press down on the fluid holes with your finger to close them, and apply compressed air to the hydraulic hose fitting end. Cover the piston opening end with a large rag, to catch the piston when it flies out.

[natejelovich]

I'm having the same problem, by my master cylinder is very different. I can't get the piston out to save my life!

I was wanting to just buy a whole new setup, because the smaller breather hole is clogged and can't seem to clean it out. It still looks blocked even after multiple cleanings. I even tried using a sewing needle to dig it out... but no luck!

[Nessism]

So to recap...

Make sure the C-clip is out, grab plunger nub with vice grip pliers or similar, push in the plunger all the way, then pull back quickly, repeat as needed until the plunger comes out.

You can't clean the master cylinder without removing the plunger. Check the small fluid return passage to make sure it's not fouled with crud.

Replace the plunger with an OEM Suzuki master cylinder kit.

Good luck

[scott]

I'm having the same problem, by my master cylinder is very different. I can't get the piston out to save my life!

I was wanting to just buy a whole new setup, because the smaller breather hole is clogged and can't seem to clean it out. It still looks blocked even after multiple cleanings. I even tried using a sewing needle to dig it out... but no luck!

I didn't see any in Tech73's pics but here it looks like part of the dust boot is still in there. My boot ripped when I tried to remove it. My master cylinder doesn't look like yours, but I couldn't get the piston out until I pulled out all of the boot pieces (it was a pain).

[natejelovich]

Yes, my dust cover ripped as well. I'll try and get that all the way out. It is definitely a pain.

[Nessism]

Yes, my dust cover ripped as well. I'll try and get that all the way out. It is definitely a pain.

You can't remove the C-clip to disassemble the unit with that boot in the way.

[natejelovich]

Cool, good to know. I was wondering about the c-clip as I couldn't see it anywhere...

Learning a ton, just wish I could get it done quicker! Thanks Nessism!

I'll keep working at the boot to remove it. Every time I grab it is just tears...

[natejelovich]

Any pro level tips for cleaning out the return port on the master cylinder?

I've taken it all apart (removed piston, etc.) and have tried several rounds of brake cleaner, and scrapping the port out with a dentist's pick and wire brush but it's still clogged with little sign of hope.

[G. Bruns]

I'd suggest using one of your smallest drill bits to drill it out. Not sure why they made that hole so tiny.

[natejelovich]

Try a drill bit on a drill. Not sure why they made that hole so tiny.

That's what I was thinking too, but worried it was designed to be that size for a reason, and not sure I can find a small enough drill bit...

So, new question is, MUST the hole be that small?

[Dogma]

Just keep at it with cleaner and a stiff wire.

Yes it needs to be that small. Machinists don't make holes that small if they can avoid it. If you want to know why a machinist was forced to make that hole, stare at the master cylinder cross section diagram in the service manual until you see how it works and why the hole is that size.