Wilwood Compact Remote Flange Mount Master Cylinder - Manual (Page 3)

Page 3
General Information and Installation Instructions
Installation of this kit should ONLY be performed by persons experienced in the installation and proper operation of disc brake systems.
Before installing the Wilwood remote master cylinder kit, read the following instructions carefully to ensure a trouble-free installation.
Reservoir Selection:
The small or large reservoir will mount directly on the master cylinder body, or in a remote location using the remote mounting bracket
(connected by the brake hose included with the kit). Use the large reservoir with two or more large displacement calipers, otherwise the
small reservoir is adequate. Always use the clamps provided with the reservoirs and remote inlet adapter. Do not over tighten.
Mounting Location:
Master cylinders should be firmly mounted to appropriate pedal assemblies and kept away from heat sources. Use tie straps, or small
hose clamps to secure hose when remote reservoir is used. Check to verify that the full stroke of pushrod is unimpeded when depressing
brake pedal and that pushrod is allowed to fully retract when brake pedal is released.
Residual Pressure Valves:
Use of an external residual pressure valve should be utilized when the master cylinder is mounted below the horizontal plane of the
brake calipers (or drum wheel cylinders).
Bench Bleeding Instructions:
• Bolt the cylinder to a pedal bracket or gently hold it in a vise. Remove the reservoir cap. Fill the reservoir approximately 2/3 full with
Wilwood Hi-Temp° 570 brake fluid (P/N 290-0632), or for severe braking or sustained high heat operation, use Wilwood EXP 600 Plus
Racing Brake Fluid (P/N 290-6209). WARNING: Do not use DOT 5 silicone brake fluid for racing or performance driving, use
only DOT 3, DOT 4 or DOT 5.1 brake fluid. Firmly push the cylinder rod all the way down and place a finger over the outlet fitting.
Let the rod return all the way before removing the finger from the outlet hole. Repeat the process until all the fluid coming from the
outlet is bubble free. Be sure to watch the fluid level in the reservoir. If the reservoir is less than 1/3 full, add fluid before further
bleeding. Temporarily plug the outlet fitting and install the reservoir cap.
Alternative Bench Bleeding Method:
• Alternative bench bleeding method: Temporarily install a pipe thread to tubing fitting and clear plastic return line (not supplied) back
to the reservoir. Slowly pump and return master cylinder piston throughout its full stroke until no bubbles return to the reservoir.
Disconnect tubing and fitting while temporarily plugging the outlet fitting, then install reservoir cap.
• Install the master cylinder in the chassis. Connect the brake line being careful not to let air into the outlet fitting. Thread the push rod
into the pedal clevis. Remove the reservoir cap and bleed the brake system as normal. Be sure to refill the reservoir if the fluid level
falls below 1/3 full. If a power bleeder is used, follow the manufacturer’s instructions.
Bleed The System:
• To properly bleed the brake system, begin with the caliper farthest from the master cylinder. Bleed the outboard bleed screw first, then
the inboard. Repeat the procedure until all calipers in the system are bled, ending with the caliper closest to the master cylinder.
• A dual master cylinder application will require three people for bleeding, one pushing the brake pedal and one each on the front and
rear of the car. Be sure to bench bleed and fill master cylinder with fluid, then install on the chassis. Elevate the right side of the car
and bleed both front wheel and rear wheel outboard bleed screws simultaneously. Repeat the procedure for the inboard bleed screws.
Lower the right side and elevate the left side of the car. Simultaneously bleed the left side front and rear outboard screws first, then
the inboard. If the brake pedal does not feel firm when applying pressure, repeat this procedure starting with the right side of the car.
• If the master cylinder is mounted lower than the disc brake calipers, some fluid flowback to the master cylinder reservoir may occur,
thus creating a vacuum effect that retracts the caliper pistons into the housing. This will cause the pedal to go to the floor on the first
stroke until it has “pumped up” and has moved all the pistons out against the pad again. A Wilwood in-line two pound residual pressure
valve, installed near the master cylinder will stop the fluid flowback and keep the pedal firm and responsive.
• After the system is bled, fill the reservoir to the max line of the top and replace the cap. Adjust the push rod for proper pedal position
and tighten the jam nut against the pedal clevis. Make sure that the pedal allows the push rod to return completely.
• Inspect for leaks at all pressure connections. Use a Wilwood Pressure Gauge (P/N 260-0966) to verify line pressure at each caliper
and to pre-adjust the balance bar, if used.
Maintenance:
Master cylinder rebuild kits are available for all bore sizes (see ordering information on the next page) and should be rebuilt periodically
(reference Figure 4, page 4). Always inspect master cylinders before and after every race for damage or leakage. When rebuilding
master cylinders, take care not to damage piston seals. Test master cylinder before usage. Use Wilwood Hi-Temp° 570 or EXP 600
Plus brake fluid as a lubricant when assembling.