Clutch master cylinder rebuild

[syncrodoka]

This is the leaky clutch master cylinder unit, the plastic supply nipple rubber seal to the unit is wet and it is starting to bypass internally. I have had a rebuild kit here for a while anticipating doing this job and images are difficult to find of the process so I documented it for posterity.

The rubber boot to the actuator rod just pops off of the unit.

The plastic supply nipple needs to be worked loose side to side while pulling outwards.

There is a spring clip that holds the hydraulic assembly together, this needs to be removed with some pick tools. As the clip starts to release work slowly and cover with a finger or push the assembly down as the internal spring will shoot everything out.

Here is the assembly partially disassembled with the parts in order.

The unit completely disassembled. Note that the square part of the spring sits against the body and the tapered side rests against the cylinder.

I had a spare clutch master resleeved to see if I can get a better life span out of it since the clutch hydraulic lifespan is quite bad. They overbore the body and press in a stainless sleeve, you can just see the sleeve here.

The rebuild kit is straightforward as long as you know which direction the seals go on, these pictures may be helpful for reference though. Lubricate the seals with brake fluid and they set in place easier.

[do.dah]

THANK YOU!!

[Italjohn]

I did a video of that as well.


Link

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[Sodo]

Perfect.

I have a low-miles master that I'd like to rebuild for a spare.
I hope it's just gummed up & not pitted.
Where do you get quality rebuild kits?
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[valvecovergasket]

[ALIKA T3]

I have rebuild a master cylinder once too.
The bore was perfectly fine, yet it lasted only a couple weeks.

I've tried a chinese master after that for like 25 bucks, it's still on the van 7 years later....
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[syncrodoka]

I spray paint hydraulic cylinders black before I install them so this was replaced by me not too many years ago.
I have run a sleeved clutch slave cylinder for several years without issue.