Master rebuild - any instructions?

[dogdude]

Hey all

Just got my rebuild kit for the master cylinder from opel source, it came with a blow up schematic of it all apart, but no real instructions. Ive read all previous posts and did a search, but nada.
Does anyone have some step by step instructions on how its done, start to finish before I tackle the job?
Please help ASAP....havent driven my baby in almost a month!!

Thanks
Mike

[soybean]

I remember reading about a rebuild within the last year. Can't remember the exact one. The only thing I can suggest even though you did a search, is to start here. http://www.opelgt.com/forums/group-5-brakes/ It's in there somewhere. Also you might try the online FSM. Wish I could be of better help. Maybe someone else remembers the thread? Jarrell

[dogdude]

Read every post in brakes that came back with master in the search, nada ...but how do i find the online factory service manual?..Didnt check there?
Mike

[opelgtboy70]

I think the search option needs to be revamped. I search for things and too many things come up. If I want engine bearings, everything that has the words engine or bearings show up. It should only show engine bearings.

Karl

[GTJIM]

Your brakes are a 'life & death' component - If you have to ask this question then DON'T try rebuilding it by yourself!
It is not the sort of thing anyone can talk you through without incurring considerable liability.
Either find someone at a VW, BMW, Audi or Mercedes repair shop who is prepared to do the job with you or find someone nearby who is prepared to show you how - hands on.
Sorry to rain on your parade - but this job is "mission critical" and has to be done right, first time. It is not just as simple as bunging the bits in right way around.

[soybean]

I think the search option needs to be revamped. I search for things and too many things come up. If I want engine bearings, everything that has the words engine or bearings show up. It should only show engine bearings.

Karl

If you narrow down the keywords and the particular area, it helps considerably. But you also have to remember there are almost 100,000 posts that have been made, so there is a lot out there. I have to wear glasses now I've read so much. Jarrell

Read every post in brakes that came back with master in the search, nada ...but how do i find the online factory service manual?..Didnt check there?
Mike

In the navigation menu on the left of the screen click and got to The Opel Tech Center. Hth, Jarrell

[opelgtboy70]

The thing about this search is that it searches opposite of any other search Ive seen. If you put in three words in other lists, it will only give you a list with those three words. This list will give you anything with a single word in it and triple the list. Thats why I think some, including myself, will ask already answered questions because it would take hours to go through all the listed items and only minutes for someone to respond to the question.

Karl
70 GT

[dogdude]

This ones back to Jim

Absolutely no disrespect intended Jim, but I cant think of a single thing mechanical that I have not taught myself too do. Played with lots of brake parts in the past, pulled them apart, experimented a little...this is how you learn to do things. What I was looking for was inside secrets, yknow, like this little hidden screw might be holding you back, ect.
If I get it wrong, it wont work properly, if at all...period.
When you have a car, especially a pretty rare car, such as ours, you have to attempt things on your own, or get a second mortgage and pay someone to do everything for you.
And when you belong to club such as this, you seek out advice and tips, then do what you can.
Just my two cents

Mike

[namba209 (R.I.P.)]

Mike, I think you have to understand where Jim is coming from, and I concur with his statement. We don't know your mechancal abilities or experience, so we're looking at your query as though it's from a limited capabilities owner. The key in his response was to make sure the car will stop when the brakes are applied after the rebuild. It is a safety related response, meant to keep you and anyone else from doing yourselves in and destroying an Opel in the process.

I ran a search, using the advanced search function in the Brakes Forum and came up with only 2 pages of threads/posts that narrowed down the search immensly. HTH.

[GTJIM]

No disrespect intended here, either. Just that it is far easier to get someone local to run through 'hands-on' than count on long distance help!
Step by step instructions for rebuilding a brake master cylinder, with all the pit-falls and things to watch for, would take an age to write - and probably miss critical things that could compromise safety.
Things like:- How badly can the bore be rust pitted? How far oversize can the bore be honed before the seals you have won't fit correctly? Are any of the parts you must re-use beyond use? Etc. etc.
Lots of this sort of thing can only be assessed by being there and seeing it.
That is why I suggested finding someone local to help. OK?

HTH

[baz]

mike it may help to think of it this way ,
as we read questions over and over by newbies , the senior members tend to tune out things and it comes down to
1: direct the person to a link to the last time it was asked (this means we have to do the searching for them and means they do not learn how to use the site to there advantage)(this also tends to result in option 3)
2: give the old chestnut out of "if you have to ask then im sorry but you dont have the skills and should get a mechanic to do it " this is true in about 95% of questions
or
3: newbies dont get questions answered as the other members have got sick of repeating themselves

[soybean]

I don't think anyone was meaning any disrespect, rather concern. It is one thing to go, but another to stop. The faster you go both increases. We have people here who have been around Opels for many a year, and some just discovered how neat, and old, they are. There’s a thread going about a manual master cylinder. Great stuff. Also another about rotors on Ebay.

There are very few Opels around, and no wants to rear end that little old lady that suddenly decided to make a left in front of you with traffic coming. You get the meaning. There are several places that have brakes and a few dollars more is worth it. Get new ones, rebuild the old ones keep them as spares, and drive safely. We do enjoy having new members.
Jarrell

[dogdude]

Just wanted to make a final post on this topic

I appreciate all tlhe thought and interest that went into these responses above. I do understand why Jim, Jarrell, Ron and Baz posted their concerns with my original post. And I do agree that safety is paramount.

And just a little background on me, Ive been skullking around this forum for over a year, joined last april. Im 40 years old, been wrenching on cars since I could see over the fender with my Dad. In the process of resto rodding three cars, my sons 79 trans-am ,my friends 57 chev and of course my 72 GT. Used to race and crewchief with a buddy of mine in local track racing up here and in Calgary for quite a few years. The only thing that I stay away from are the inside of a tranny (never did like brain surgery).

So, as a result, I am going to plan B - cut big hole in floorboard, put on Fred Flintstone Rubber Feet, attatch fifty foot section of rope to boat anchor, ..... wait maybe thats not such a good idea, I d look pretty silly in those Flintsone Feet...hmmmm.

Going to try and find some time to do the master this weekend. Will post the end results.
Mike
Thanks again for the concern

[West Coast GT]

How about a followup to tell us how the master brake cylinder rebuild came out?

Everything work OK? Or are you currently in traction sipping your meals through a straw?

What worked?
What didn't work?
What would you do differently next time?

[Anonymous D]

A simple reference to:

http://www.opelclub.com/html/brakes.html

Would have revealed, that this topic was
covered in a step-by-step article,
in the OMC Blitz of June 2004.

Cost: $2.00

[dogdude]

First off, Sorry I didn't post the follow-up, wife has had me so damn busy doing renovations, completely forgot to post how the rebuild went.

The kit i got from GT source was complete( a little pricey mind you) and the rebuild was quite easy once i tore it apart and compared it to the schematic that came with the kit.

Thanks to all the tips i found with the search feature, taking the master out was easy, simply popped off the resovoir, unbolted the retaining nuts, unhooked the brake lines and voila...onto the bench.

All in all, went without any problems, wouldn't hesitate doing another one. The brakes are absolutely great compared to where they were.

Now the only problem I'm having is trying to get the car going fast enough to use the brakes! Just installed a new weber carb, and still haven't got it dialed in yet, but i'm working on it.

Best tip i can come up with is search the forum for past experiences and when in doubt, do what i do....call Kwilford and ask for advice! (thanks again Keith)...lol.

Mike

[opelgtboy70]

I didnt check the price of a kit, but a rebuilt master cylinder is about $50.00

Karl
70 GT

[West Coast GT]

Encouraged by your good experience I am rebuilding my master brake cylinder.

I have a question for you. Located on the front of the cylinder (the end facing the front of the car) is a small bore that appears to house a spring-loaded piston assembly that has something to do with the brake failure switch. This bore is not shown in the diagram that came with the re-build kit. The piston assembly doesn't move forward or backwards. The spring action seems to be gone. I cannot remove it from the bore.

1. Is it necceassy this piston assembly function; or will it negate the front and/or rear brakes from operating?

2. How do I remove this assembly?

[dogdude]

Is this what your talking about?

If so, yes I removed everything, and mine came out without any effort, and the only thing I do remember is to make sure they go back in the exact same way they came out.

brake shematic opel.jpg

[West Coast GT]

Yes, that looks like the smaller bore I referred to. Unfortunately the resolution on your schematic doesn't allow me to read it. Could you tell me where to fine one?

Thanks