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 Post subject: Brake Master Replacement
Unread postPosted: Mon Jun 08, 2009 12:08 pm 
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I had been leaking brake fluid slowly and knew it was seeping from the nose (front) of the master cylinder. On the shelf in the garage was a brand new German cylinder that I had purchased several years ago. It was time to change.
First, you must get flare nut wrenches. The nuts on the metal brake lines are really soft and can get damaged easily. I got some wrenches from Harbor Freight that were like the head of an end wrench and then you snapped in a 3/8" extension to turn it. They worked OK, but I'd also advise getting an 11 mm flare nut end wrench.
The old m/c:
Image

Note that some PO had tried to use a zip tie on the rubber boot.
Do drain all the brake fluid out of the cylnder, supply lines and reservoirs before you start to pull the lines. Brake fluid tastes really nasty.
Here are the old greasy parts:
Image

And now the clean parts and the new m/c:
Image

And finally installed:
Image

To get those three hard lines threaded on was tough. You need to start everything (including the two mounting bolts) first before thightening things down. I did not bench bleed the m/c before installing it. I figured that having more brake fluid leaking out would make things worse. After I got it all installed I could not get any brake pressure. Following Bentley, or Muir or Colin or someone's instructions I just cracked open the hard line fittings on the cylinder, pumped the pedal a few times and that got the cylinder bled enough to pressurize.
The reservoir up under the dash (this is a '69) is a 68/69 only item and NLA. The hose that runs from that reservoir to the one on top of the cylnder is also unique and NLA. This NLA hose requires a bushing to fit and seal on the tank on top of the cylinder. Thanks to God that VeeParts had this very unique bushing.

And everyone remembers to bleed the system well at the wheels before driving, right?

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Turns out that the Deep State might be a Republican operation. Hmmmm.
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Unread postPosted: Mon Jun 08, 2009 12:27 pm 
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OB Bus wrote:
Brake fluid tastes really nasty.


:smt078

Please explain how you found this out. :lol:



As for last statement.... I always make sure I can stop before I can go.

Thanks for the nice little write up.

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 Post subject:
Unread postPosted: Mon Jun 08, 2009 12:45 pm 
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Job well done!! :smt041 . I know sooner or later my 68 will need some work on the brake system. That little reservoir under the dash is one of the hardest parts to find for that year. I had an extra that needed a little work and gave it to Pyro some time ago.




:smt040

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 Post subject:
Unread postPosted: Mon Jun 08, 2009 1:10 pm 
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You should see the one I used as a replacement! :razz:

Talk about brakes, I just worked on the Plump Truck this weekend. It was pulling to the left BIG time so I "fixed" the right one and now, well, it's pulling to the right!?! :sad:

Not so bad as it was before. I'll give it time to "set" into it. :cool:

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Last edited by pyrOman on Mon Jun 15, 2009 5:32 am, edited 1 time in total.

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 Post subject:
Unread postPosted: Mon Jun 08, 2009 1:14 pm 
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Did you change the hoses?

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Turns out that the Deep State might be a Republican operation. Hmmmm.
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 Post subject:
Unread postPosted: Mon Jun 08, 2009 1:22 pm 
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pyrOman wrote:
You should see the one I used as a replacement! :razz:

Talk about brakes, I just worked on the Plump Truck this weekend. It was pulling to the left BIG time so I "fixed" the right one and now, well, it's pulling to the right!?! :sad:

Not so bad as it was before. I'll give it time to "set" into it. :cool:


My CS was pulling to the right, I put more brake fluid in and proplem solved, for me !! :grin:




:smt040

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 Post subject:
Unread postPosted: Mon Jun 08, 2009 2:05 pm 
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Fricken crazy people. Note to self, stay behind Ivan and Chris in a caravan. :lol:

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 Post subject:
Unread postPosted: Mon Jun 08, 2009 10:23 pm 
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der58SC wrote:
Fricken crazy people. Note to self, stay behind Ivan and Chris in a caravan. :lol:


Don't know what would be worse!! If they can't stop and/or lock up.... :lol:

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 Post subject:
Unread postPosted: Tue Jun 09, 2009 6:19 am 
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if they lock up, at least you can try to avoid it. If they can't stop and you are in front well.... you are....

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 Post subject:
Unread postPosted: Tue Jun 09, 2009 8:47 am 
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Brooks wrote:
der58SC wrote:
Fricken crazy people. Note to self, stay behind Ivan and Chris in a caravan. :lol:


Don't know what would be worse!! If they can't stop and/or lock up.... :lol:


Hey Now! Hey Now! So far stopin has not been a problem, a little pullin now thats just part of the adventure of drivein a VW. Have you ever had a white knuckle brake experience??
Note to self-- :slap: Check me Brakes!!!




:smt040

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(Chris C.)

"Marine Sniper - You can run, but you'll just die tired!"

56 Kombi (The Slayer Bus)
65 Sundial Camper
68 Single Cab
61 Rag Top
03 Passat
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 Post subject:
Unread postPosted: Wed Jun 10, 2009 12:43 pm 
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Nice write up Larry, looks like I will be following in your footsteps and not only going through my braking system but will be upgrading to the Dual Circuit M/C in the near future.
Question, will I need to remove the ball bearing thingy you know the one that keeps constant pressure on the front brakes like I did for my disc brake conversion?


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 Post subject:
Unread postPosted: Wed Jun 10, 2009 2:27 pm 
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robzdoka wrote:
Question, will I need to remove the ball bearing thingy you know the one that keeps constant pressure on the front brakes like I did for my disc brake conversion?


Never heard of the ball bearing thingy. Should I have? Anyone else help here?

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Turns out that the Deep State might be a Republican operation. Hmmmm.
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 Post subject:
Unread postPosted: Wed Jun 10, 2009 2:29 pm 
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interesting question. Could this ball bearing thingy be right next to the blinker fluid? :lol:

OK Seriously, I have no idea what you are talking about Rob.

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 Post subject:
Unread postPosted: Wed Jun 10, 2009 2:39 pm 
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der58SC wrote:
interesting question. Could this ball bearing thingy be right next to the blinker fluid? :lol:

OK Seriously, I have no idea what you are talking about Rob.


I hope he also has been checking his radiator fluid.
--Dan


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 Post subject:
Unread postPosted: Wed Jun 10, 2009 7:31 pm 
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Dorks :grin:
When converting to disc brakes I was told to remove the residual valve (I'm pretty sure that's what it's called) from the master cylinder to keep the front disc from dragging.
I know there was a write up somewhere on TS, I'll go look for it.


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 Post subject:
Unread postPosted: Wed Jun 10, 2009 8:34 pm 
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OB Bus wrote:
robzdoka wrote:
Question, will I need to remove the ball bearing thingy you know the one that keeps constant pressure on the front brakes like I did for my disc brake conversion?


Never heard of the ball bearing thingy. Should I have? Anyone else help here?


residual pressure check valve. if it/they are on master. if on rear line then it is a hoodiggy thingie.

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http://www.thesamba.com/vw/forum/viewtopic.php?t=453617


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 Post subject:
Unread postPosted: Wed Jun 10, 2009 8:45 pm 
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bill may wrote:
if on rear line then it is a hoodiggy thingie.



OH SNAP!

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 Post subject:
Unread postPosted: Thu Jun 25, 2009 6:09 am 
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Thinking about doing the D/C change over this weekend but I'm in need of the rabbit reservoir. Bill do you have one you'd be willing to sell?


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 Post subject:
Unread postPosted: Thu Jun 25, 2009 6:40 am 
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do a tech article mang. Get one of the boys to hold the camera and snap pics. :cool:

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If 4 out of 5 people SUFFER from diarrhea....does that mean that one out of five enjoys it?


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 Post subject:
Unread postPosted: Thu Jun 25, 2009 7:22 am 
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robzdoka wrote:
Thinking about doing the D/C change over this weekend but I'm in need of the rabbit reservoir. Bill do you have one you'd be willing to sell?


maybe,but there are lots at the boneyard. you should do the euro show and do the change over another time. i could maybe help you do it.

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