General information and installation instructions, Photographic tip – Wilwood Combination Remote Master Cylinder User Manual
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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). Master cylinder internal residual pressure valves should not be used.
Bleeding Instructions:
Master cylinders should be bled while mounted to the brake pedal assembly. NOTE: The master cylinder includes a bleed screw for
easy in-place bleeding and that either outlet may be used for the bleed screw/outlet fitting. Connect all brake lines after the master cylinder
is installed, but prior to bleeding. Review the following steps:
• Connect a clear bleed hose with catch bottle to master cylinder bleed screw.
• Wilwood Hi-Temp° 570 Racing Brake Fluid or EXP 600 Plus for extreme performance situations (or alternate high temperature DOT 3,
DOT 4 or DOT 5.1 brake fluid) is highly recommended for race cars and high performance vehicles where brake temperatures exceed
normal operating conditions. NOTE: Silicone DOT 5 brake fluid is NOT recommended for racing or performance driving.
• Fill reservoir with Racing Brake Fluid.
• Open master cylinder bleed screw.
• Gently depress brake pedal.
• Close master cylinder bleed screw and gently release brake pedal.
• Repeat the above steps until fluid from master cylinder is free of air. Close master cylinder bleed screw.
• 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.
NOTE: When using a new master cylinder, it is important to bench bleed the master cylinder first.
•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.
•Test the brake pedal. It should be firm, not spongy and stop at least 1 inch from the floor under heavy load.
If the brake pedal is spongy, bleed the system again.
If the brake pedal is initially firm, but then sinks to the floor, check the system for fluid leaks. Correct the leaks (if applicable) and
then bleed the system again.
If the brake pedal goes to the floor and continued bleeding of the system does not correct the problem, a master cylinder with
increased capacity (larger bore diameter) will be required. Wilwood offers various lightweight master cylinders with large fluid
displacement capacities.
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Photographic Tip