| Disc-Brake Conversion: Brake Master-Cylinder Replacement |
From "Weekend Mechanic"
episode WKM-210 |
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The final steps in the disc-brake conversion include installation of the brake master-cylinder and connecting and bleeding the brake lines. Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type of brake-conversion kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts. Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools or with hazardous chemicals such as brake fluid.Master Cylinder
- Before installing the new master cylinder on the vehicle, it must first be bled using a specialized bleeder kit. Begin by loosening the clips that hold the cap in place, then removing the cap (figure A).
- The master-cylinder bleeder kit (figure B) comes with tubing, clips and multiple adapters.
- Follow the directions that come with the kit to select the suitable adapters, then connect the adapters and tubes to the ports on the cylinder. The other ends of the tube extend down into the master cylinder, and are held in place by a plastic clip (figure C).
- With the bleeder kit installed, fill the master-cylinder about half-way with new brake fluid. Use a large screwdriver to depress the valve assembly inside the master cylinder (figure D).
- Small bubbles will appear in the fluid. Continue working the valve assembly until no more bubbles appear. This indicates that the cylinder has been thoroughly bled.
- With the cylinder bled, detach the bleeder kit and place the cap back on the master-cylinder (figure E).
- Unbolt the old master cylinder (figure F), detach the brake lines and remove the cylinder from the firewall.
- Position the new master cylinder in the same location (figure G), and bolt it in place using new washers and nuts (figure H).
- Make sure all of the connections are tight -- particularly the connection to the brake lines (figure I).
- With the new rotors and master-cylinder installed, the brakes can be bled. We bled the lines, according to our vehicle's service manual, using a capture cup and clear tubing connected to the caliper (figure J).
- Monitor the bleeding of the lines, and checking for leaks, while a helper sits inside the vehicle and pumps the brake pedal (figure K). During the bleeding process, be sure to add brake fluid as needed to avoid air in the lines.
- With the installations complete and the brake lines bled, reinstall the wheels and tires to complete the project, then take the vehicle for a test drive.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
Automotive Brakes and Antilock Braking Systems
Model: 0314028382
Author: Kalton C. Lahue
(1995)
To order this title from Amazon.com, click here.
Delmar Learning
Brake Handbook
Model: 0895862328
Author: Fred Puhn
(1985)
Order this book from Amazon.com.
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