giorgio67

brake master cylinder rebuilt

40 posts in this topic

HI guys,

no much time in these days to be working on my car (mummy... :) ) anyway I have started to rebuilt my brake master cylinder.

I'm sure it's an easy job for most of you but I think it will be good for someone to see a step by step description of the job.

Hope could be useful for some "novice" member.... :kiss:

Ciao

Giorgio

DSC00036.jpg

o'ring and circlip removed

DSC00037.jpg

DSC00038.jpg

then you need to remove seals and then the primary plunger will come out

DSC00039.jpg

then remove the top rubber seal and the little "screw" fixing the secondary plunger taking care as there is a pushing spring....keep it!!

52faf0ac.jpg

a good degrease and wire brush on the body

DSC00045.jpg

and it's ready for two coats of special paint

finished job

DSC00048.jpg

tomorrow I will paint the pump and install new seals and gaskets.

I will put some pics of the process.

Ciao :P

Edited by ghe67

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Upgrade today to remove Google ads and support TLF.

Giorgio, my master cylinder was slightly different. It had 2 white plastic discs, each thinner than the one in your photo and separated by a spacer. This turned into a major pain as one disc would fall into a recess in the bore and get stuck so I couldn't get the plunger out. I ended up drilling the disc and fitting 2 screws into it so I cold pull it out. I then made a new one out of nylatron.

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Make sure you check the bore of the cylinder...they are very prone to rust as brake fluid absorbs water, which settles on the bottom of the master cylinder bore...and,as nobody changes the fluid often enough, it corrodes and starts leaking past the seals. Clutch system does the same. Once it's got to this point, changing the seals won't help. If there is only light corrosion, honing the cylinder maybe able to restore it...this was standard practise at the London Fire Brigade motor vehicle workshops, and fire appliance brakes have to work!!

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HI,

just some pics of the finished job.

The bore is perfect so just new seals and gasket.

Lucas kit

DSC00050.jpg

secondary plunger rebuilt

DSC00051.jpg

Freshly painted with special paint

DSC00052.jpg

finished!!!

DSC00053.jpg

Wow!! :)

DSC00054.jpg

Very good result!!

CIAO

Giorgio

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Giorgio, if you carry on like this you will have to publish the "Taricco Guide to Rebuilding the Esprit"!! There isn't anything available with the level of detailed illustration that you are producing. And as for the standard of your work; well, I end up with things that work and look presentable...you stuff is better than new out of the box. Clean and shiny isn't in it!! Carry on with the good work..wait until you start DRIVING the beast. Do you do subcontract work?!!

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:rant:

thanks mate!!!

....wait just a moment and you will see the "Engine rebuild section" "Suspension& Brakes" and How to paint your Esprit!!! :)

Ciao

Giorgio

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Oh that looks all nice and clean...I love putting nice bits back on to my car!!!

Well done

Buddsy :unsure:

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Hi Gorgio

Where did you get the overhaul kit from? Any part numbers you can share?

Kind regards

Brandt

Edited by Brandt

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Hi Brandt,

I bought the kit on ebay for 2 GBP some time ago.

I have the empty box in my workshop, so I will check the part number and I let you know as soon as possible.

Regards

Giorgio

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Hi Brandt,

just checked the part number.

Lucas/Girling Brake master kit SP7651

Regards

Giorgio

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If I want to replace the full master cilinder (not repair it), where Is it coming from? I mean wich other Brit car uses the same?

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Hi Franky,

brand new item...here http://cgi.ebay.it/LOTUS-ESPRIT-BRAKE-MAST...1713.m153.l1262

I think only the tank fluid is different from mine, anyway be aware that if it's a really "old stock" the gaskets and seals could be dryed....

Hope this help.

Regards

Giorgio

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Thanks a lot...will try to get this one!!!

Ciao!!!

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DSC00039.jpg

52faf0ac.jpg

DSC00048.jpg

Hi Giorgio

I hope you can help me with the rebuild of my S2 master cylinder. I have installed new seals but the brake pedal is very poor even after bleeding many times, which leads me to think i have installed one of the seals incorrectly, see arrowed seal. One of my cylinder pistons is different to yours, it has an extra seal ( arrowed ) and i am not sure if it is correctly positioned. All the other seal positions are the same as yours except this one which is not on yours. Would you know if the position of ths seal is correct? if it is i must be bleeding the brakes poorly. Also, all the S2's i have seen have the brake resevoir filler next to the servo, mine is opposite to this, does the position of the resevoir on the cylinder matter? could this cause me to have a 'poor' brake pedal?

Chris

blablas.jpg

blabla2b.jpg

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Hi Chris,

I can't unswer your question about the different piston as I've never seen one but regarding the fluid reservoir, yes it could be the problem.

If you look at the top of the body where the reservoir is mounted you will see that one hole has a inside seal.

Did you change it?

The other is different.

The mountings of the reservoir are different, so you can't mount it as showed in your pic, in this way you have a leak from the top of the pump.

Hope this help.

Regards

Giorgio

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Hi Giorgio,

thanks for that, i,ve got a day off tomorrow to see if i can fix it

Chris

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I'm trying to rebuild my cylinder: I can't get the pin out from the brake pedal as the steering column is in the way, so I took the BMC off seperately and tried to strip it but can't get the white nylon disc out. I got as far as photo 3 "then you need to remove seals and then the primary plunger will come out" which seals are these? Does anyone know where I can get the nylon disc? As I may need to drill into it. :(

Brilliant thread and photos Giorgio! :D

Edited by surferphil

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You don't need to drill it, just blow it out with compressed air.

Paul.

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I'm trying to rebuild my cylinder: I can't get the pin out from the brake pedal as the steering column is in the way, so I took the BMC off seperately and tried to strip it but can't get the white nylon disc out. I got as far as photo 3 "then you need to remove seals and then the primary plunger will come out" which seals are these? Does anyone know where I can get the nylon disc? As I may need to drill into it. :(

Brilliant thread and photos Giorgio! :D

As Paul says you can use compressed air or tap the cylinder, white nylon disc down, onto a timber bench like i did and loosen it that way. Is there any chance of you taking some photos of the pistons/seals when its apart?, i still hav'nt sorted mine out yet

Chris

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I tapped it quite a bit and it's stuck in there, I'll try my friends air compressor and see if that does the trick.

I'll take some photos too. :D

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I got the first piston out with a little help form a drill and 2 screws :( No amount of tapping banging and pfafing with an air compressor was going to shift the poly spacers! I left it for a few weeks but sadly it didn't fix its self.

Here's a photo so far:

BMC.jpg

Edited by surferphil

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can anyone advise what these are off - landrover 90 by any chance ????

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I think they may be off the Morris Marina, maybe also the Ital to keep the Giugiaro link.

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here's a Landrover 90 one.

post-5137-1249848816_thumb.jpg

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2ndaryPiston.jpg

This is as it was when I took it out of the BMC. 2ndary Piston assembly.

I hope this is helpful.

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