Hydraulic System: Service Precautions

WARNING:
Brake Tube Replacement
^ Copper tubing should not be used in the hydraulic system. Use only SAE J526 or JS27 steel tubing, or equivalent. Tubing other than the proper steel tubes may burst and cause brake failure.
^ When bending brake tubing to fit underbody, be careful not to kink or crack the tube.

System Contamination
^ Brake fluid contaminated with a hydrocarbon/mineral based fluid (such as power steering or transmission fluid) can be detected by an obvious swelling of the master cylinder cap gasket.
^ If the SWOLLEN brake master cylinder gasket condition is present, ALL brake system rubber parts must be replaced. ALL components containing rubber parts must be overhauled or replaced. ALL brake tubes must be thoroughly flushed with brake fluid before the vehicle goes back into service. Contaminated and swollen parts can lead to brake FAILURE.

Caliper/Master Cylinder Piston Removal
^ Use only as much COMPRESSED AIR as necessary to remove pistons. Excessive pressure can force the piston out of the bore with enough force to cause personal injury. NEVER attempt to catch the piston by hand as it comes out of the bore.

CAUTION:
Pressure Bleeding Hazard
The bleeder tank should be charged with 68.6-205.8 kPa (10-30 psi) of air pressure. Never exceed 343 kPa(50 psi) of pressure.
^ Do not allow the brake master cylinder reservoir to run dry during service operations. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse brake fluid that has been drained from the hydraulic system.

Alcohol Damage
^ Do not use denatured alcohol for flushing the system or cleaning assemblies where alcohol could be trapped and cause eventual failure of rubber components in the system. Denatured alcohol is acceptable for cleaning parts, provided the parts are completely air-dried and coated with brake fluid before installation.

Brake Fluid Damage
^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.