PDA

View Full Version : Putting the clutch master cylinder back together



tdskip
12-08-2009, 04:33 PM
OK - so here is the documentation on putting the clutch master back together. Please point out any errors so I can correct the steps.

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-32.jpg

Getting ready to be honed;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-21.jpg

Spray the bore with WD40 to help prevent scoring the bore;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-6.jpg

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-4.jpg

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-5.jpg

I've been coached not to "over" hone the clutch M/C, a little will do;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-3.jpg


Wash it out well using tap water;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-31.jpg

Dry it out in prep for the rebuild;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-30.jpg

Ready for the plunger to be rebuilt now;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-2.jpg

tdskip
12-08-2009, 04:39 PM
OK - time to start the plunger;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-29.jpg

You first have to "unlock" the spring assembly, you do that bu gently lifting up on the tab;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-26.jpg

Once you do that you can separate the piston;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-12.jpg

You then remove the rubber ring on the pistion

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-24.jpg

Peel it all the way off

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-23.jpg

Then push the new one one. The side with the indentation/ring faces back towards the spring like shown here;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-22.jpg

tdskip
12-08-2009, 04:45 PM
Next is the spring and fittings on the other end;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-19.jpg

Pull the "crown" fitting down;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-19.jpg

And then peel off the rubber boot. if you look closely you can see how torn up this one was, hence the leaking.

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-18.jpg

Put the new rubber on

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-17.jpg

Put the curved washer and crown back on

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-15.jpg

It should look like this when it is ready to rejoined with the piston

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-13.jpg

Guide the spring up over the end of the piston and then press the tab back down securely;

https://i207.photobucket.com/albums/bb73/tdskip_photos/TR4a/TR4aclutchmastercylinderreassmbl-8.jpg

It is now ready to be reinstalled!

TR3driver
12-08-2009, 05:13 PM
Then push the new one one. The side with the indentation/ring faces back towards the spring like shown here;
A little clean brake fluid will help lubricate the process.

TR3driver
12-08-2009, 05:18 PM
And then peel off the rubber boot. if you look closely you can see how torn up this one was, hence the leaking. I'd call that a "seal" rather than a boot. Normally, it's easier to remove/install over the small end <<GRAEMLIN_URL>>/grin.gif

Overall, it all looks good to me. Two bits that perhaps could be clearer : sliding the link (inside the spring) to one side to remove it from the cup-shaped clip, and being sure the link fits into the center of the piston when reassembling the clip onto the piston.

Good work, Tom!

mrv8q
12-09-2009, 12:34 AM
Tom, don't forget the circlip; I didn't know about mine, and Randall pointed me in the right direction (as usual)...
https://www.britishcarforum.com/bcforum/ubbthreads.php/topics/557339/2

TR4nut
12-09-2009, 08:42 AM
Tom-

Excellent stuff here - any thoughts of saving it to the Wiki for future use?

Randy

tdskip
12-09-2009, 09:55 AM
Tom, don't forget the circlip; I didn't know about mine, and Randall pointed me in the right direction (as usual)...
https://www.britishcarforum.com/bcforum/ubbthreads.php/topics/557339/2

I put it back, but didn't document it. I should have, especially having just read that post where some PO never reinstalled it! Yikes.

Thanks for pointing that out Kevin!

tdskip
12-09-2009, 09:59 AM
Tom-

Excellent stuff here - any thoughts of saving it to the Wiki for future use?

Randy

That is what I was thinking Randy. I've learned so much from everyone here so when I have to do something that I haven't seen documented (or with as much focus on newbies like me) I try to write it up. The Buckeye Triumph site does have a very good write up, but I thought that some additional pictures of the details might help.

I have fooled around with the wiki yet, can I largely just cut and paste?

angelfj1
12-09-2009, 10:41 AM
Tom: This is great stuff - nice job!

RonMacPherson
12-10-2009, 07:32 PM
One thing, on reinstalling the clip, it's a good idea to make sure you install it properly. There will be a bevel edge and a sharp corner edge. The sharp corner needs to go in properly.

TR3driver
12-10-2009, 07:44 PM
Photos seem a little dark ...

tdskip
12-10-2009, 10:51 PM
Ahola Ron - good point. Thanks.

Randall - My camera doesn't like the white paper towell in the background, will try a different surface next time.

TR3driver
12-10-2009, 11:03 PM
Tom, Irfanview is really cheap (free), and does a good job at fixing things like that. https://www.irfanview.com/ The photo I posted above is a copy of yours, with just a quick crop and shift-U.