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brake master cylinder rebuilt - Suspension/Brakes/Wheels/Hubs/Steering/Geo - The Lotus Forums #ForTheOwners Jump to content


brake master cylinder rebuilt


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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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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.

S4 Elan, Elan +2S, Federal-spec, World Championship Edition S2 Esprit #42, S1 Elise, Excel SE

 

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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!!

Scientists investigate that which already is; Engineers create that which has never been." - Albert Einstein

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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?!!

Scientists investigate that which already is; Engineers create that which has never been." - Albert Einstein

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  • 1 month later...
  • 4 weeks later...

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?

Franky

Lotus Exige S2

Lotus Esprit S2 JPS #27 -restoration process-

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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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  • 1 month later...
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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  • 2 weeks later...
Guest surferphil

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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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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Guest surferphil

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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  • 1 month later...
Guest surferphil

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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  • 4 months later...
Guest surferphil

Is there supposed to be a pin in this hole? I only have one pin to put back in but being 6 moths with the BMC in bits I can't remember and it's possible I lost a bit when i took it all home with me from the workshop. :ph34r:

BMCPin.jpg

Edited by surferphil
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