Brake master cylinder overhaul #1

I started the overhaul of the brake master cylinder after the clutch slave cylinder.

This day’s work was removal and disassembly of the brake master cylinder.

My “onboro ALFA” is early type (Mk. I) 1750GTV RHD. The brake master cylinder is made by BONARDI and it is installed on the frame under the floor together with the clutch master cylinder (this is made by BENDITALIA).

Regarding the removal, there was a little try and error.

(1) Remove the pipes

Then, I tried to separate the linkage rod connecting to the brake pedal. However, the fixing nut was so hard that I changed the process.

(2) Remove the bolts fixing the brake master cylinder on the frame.

(These bolts were also fixing the clutch master cylinder penetrating the frame.)

(3)&(4) Separate the linkage rod from the brake pedal, and remove the brake master cylinder together with the linkage rod.

(The linkage rod and the pedal were fixed by a split pin.)

Next was the disassembly of the brake master cylinder.

(5) Fix the linkage rod with vise and remove the fixing nut. Then, separate it from the rod of the brake master cylinder.

(6) Remove the piston inside the cylinder. At first the piston was sticking with rust and could not be removed. However, after moving it several times, rust was gone and the piston could be taken out.

(7) The condition of the piston was not bad.

(8) There was no remarkable scratch inside the cylinder. It was also good condition.

(9) Disassembled parts.

I heard that the quality of the reproduction parts of the BONALDI type brake master cylinder was not good. Therefore, I thought it would be better to overhaul and use the original brake master cylinder. I was a bit relieved with knowing that the condition of the brake master cylinder was good and it could be reusable. ♪

(My original blog was written on 8th Jun 2009)

Comments

Tip to repair rubber parts

I disassembled the rear axle before. There had been no progress on it because I started the repair of the fuel tank during my summer holiday. While painting the fuel tank , I repaired the torn rubber boot of the parking brake wire. I guessed it didn ’ t cost high because it was small rubber part. But I wanted to try the repair method I read on the magazine article before. This was the condition before the repair. The rubber was torn apart and separated almost. I used this self-adhesive type butyl tape. I pasted lots of small pieces of the butyl tape on the back side of the rubber boot. As time goes by , these tapes would melt and stick together. After this I applied plenty of adhesive “ Super X Black ” on the rubber boot. On the magazine of MOTO MAINTENANCE , I read the article that the motorcycle seat was repaired with this method. So , I wanted to try it. After drying 1 day , it became like this....

Pad spring repair

One of the springs to hold the brake pads was broken. At first I thought to buy it, however, I tried to fix it using rivets. It seemed to be strong enough just to hold pads. Later I removed the rust and cleaned them. Note: I have been using this repaired pad soring for 10 years and there is no issue. Pad spring is not an expensive part ptobably (I don't know the exact price), but it is easy to repair if you have ar1750gtv hand rivetter. (My original blog was written on 10th May 2008 )

Body repair around the fuel tank

I found some rust at the flange in body around the fuel tank as I expected. I believed this level of rust in this area was quite usual for old Alfa Romeo. It seemed that this area didn ’ t influence on the body strength , however , I was considering the method what I could do by myself. Anyway in order to prepare the sheet metal for the repair at first , I started to look for the store where I could buy some sheet metal near my house. I tried to research the store on internet , but I couldn ’ t find appropriate stores. Finally I asked the person at repair shop , who did maintenance of my Renault 5 , about the store I could buy some sheet metal. They kindly taught me the store , but at the same time they gave me some sheet metal for free. That was enough volume for what I wanted to do. I didn ’ t expect it. Thanks a lot!!! (My original blog was written on 12th Sep. 2008 )

The day my "onboro ALFA" would revive

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