Tuesday, September 30, 2008

@#$%^&* Brake master cylinder!


After beating my head against the wall trying to get the circlip out of the brake master cylinder, I finally took it up to Bob's place and let him do the same. After he got the circlip out, we still couldn't coax the nylon washer out of the barrel, so we tried an innovative device that had worked for him before. Take a 4' 2x4 and drill a hole in it to accommodate the barrel, then screw the cylinder assembly to the board with the piston rod sticking out through the hole. Then, thump the thing against something hard. I broke two 2x4s trying to get the thing to give up its guts. Finally, we melted the nylon washer and then pulled out a rubber cup, metal washer and lo and behold, there was another circlip way down in the barrel! Grrrrrrrr. No wonder the Factory Stag manual doesn't even mention rebuilding the damn thing! The above picture is from the Haynes manual, and I wish I had paid it more attention before wasting Bob's time and mine. Eventually, Bob got the whole thing apart, and it looks to be rebuildable, so that saved me a few hundred dollars, since I do have a rebuild kit.

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