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If the primary cup fails, the master cylinder willbypass。 In other words, applying steady pressure to the brake pedal will result in it slowly sinking to the floor。 If the secondary cup on the primary piston fails, it can cause the rear reservoir level to drop and the front reservoir level to rise as fluid bypasses the damaged cup。 If a secondary cup on a secondary piston goes bad, fluid will leak out of the rear of the master cylinder。Figure 2-4: A master cylinder piston with primary and secondary cups。

In order for fluid to enter the cylinder, it is necessary for atmospheric pressure to act on the suce of the fluid。 The fluid is actually pushed into the cylinder bore by atmospheric pressure。 However, air contains moisture and we have already seen that moisture and brake fluid don’t mix。 In order to prevent moisture contamination of the brake fluid yet allow air pressure to act on the fluid, all master cylinder caps use a diaphragm type gasket。 This diaphragm seals the top of the cylinder so fluid can’t spill out but is flexible so that it will allow the fluid to move into the cylinder area。

As the fluid level drops, the diaphragm extends downward to follow the fluid level。 The diaphragm must be replaced if there is evidence of leakage around the top of the reservoir。 If the diaphragm is soft, and expanded greater than the reservoir cover, the brake fluid has been contaminated with a petroleum based fluid such as power steering or automatic transmission fluid。 In this case, all of the rubber components of the brake system will have to be replaced and the system flushed with denatured alcohol or brake fluid。

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