02GF74
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| posted on 14/8/06 at 08:48 AM |
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Master cylinder woes
On Satruday I sorted out the front flexi-hose problems. Made stainless steel disc and ali discs to clamp the rubber grommet in the side panel so that
will stay put and put a bit of twist so the hoses will drop down on full lock and not rub on the tyre. Brill!! ........ until I tried to bleed the
brakes. 
The brake pedal was not returning so after trying self-bleed and easi-bleed, the latter being perfect if you want brake fluid pissing about
everyhwere, no joy.
A closer look revealed that the clevis was not bolted to the pedal - my fault  - so more stuff undone to rectify that ... and that made no
difference. Problem is inside the master.
So more stuff removed and out comes tha master and the first question.
What Ford car/model is this master cylinder from?
 
master side view
From various Haynes manuals it is not Cortina (servo), not mk2 escort (2 port) nor Capri.
This has 3 metric ports, 2 at front for front brakes and one rear for rear brakes. It looks like the one shown in Fiesta and Sierra manuals. The
date moulded to the reservoir is 6/82 so matches the Fiesta/Sierra dates.
There is a plethora of what I suspect to be useless numbers, stamped on the body plus on the plastic tag as follows:
66315 92 38/62
7446(or 8)6(or 8)0862
The diameter of the piston is about 22 mm.
I have been unable to remove the primary piston. The circlip is out and compressed air plus a small expanding puller (M5 bolt with clutch pipe) have
failed to extract it.
So how can I get this out?
I am going to try a rawl bolt (the expanding cone type) as a last result if I can get one small enough.
Both manuals state there is a pin to hold the secondary piston in place and the primary piston should just pop out, yeah..... (unless it is this pin
stopping the primary piston?)
It seems this pin is accessible after removing the reservoir - anyone know about this and how to pull off the reservoir without damaging it? (lever
off using wooden wedges?)
If I fail to extract the piston, then are new master cylinders available, from whom (Ford?) and any idea of £?
Photo below shows how I have manged to pull out the the primary piston - not far enough
 
primary piston stuck
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paulf
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| posted on 14/8/06 at 08:55 AM |
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Looks like it could be sierra or mk3 escort to me, the mounting flange centres are different on them however so not interchangable.I will try and
measure a couple later today .
Paul.
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iiyama
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| posted on 14/8/06 at 09:00 AM |
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Agreed. Looks like a sierra to me.
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Macbeast
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| posted on 14/8/06 at 09:10 AM |
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Looks just like my Sierra one but it's 40 miles away today so can't check numbers today.
Book says reservoir just pulls off the main body but not done this myself.
Also says "circlip AND WASHER" I think you must have removed a washer as can't see on your pic.
If pedal was not returning and piston stuck, sounds as if pistons are rusted into MC body. Is there any free movement ? If so, push pistons back into
body and make sure the bit of bore you can see is absolutely crud free.
Sounds like typical Haynes manual where it says "undo the nut " as if you didn't need to burn it off in real life 
[Edited on 14/8/06 by Macbeast]
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BKLOCO
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| posted on 14/8/06 at 09:40 AM |
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Could also be a Transit RWD M/C They are similar to Sierra.
The sierra had loads of different ones fitted. (Whatever Henry could lay his hands on cheap at the time I think )
Experience is what you get when you don't get what you want!!! 
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02GF74
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| posted on 14/8/06 at 09:57 AM |
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there metal on whcih this is mounted is sloping to ensure the reservoi is level.
hmmm, wahser .... you're right, not in photo nor do I remember removing one .... hmmmm.....
probably best get a new one I think.
re: buy a aftermarket one from one of the online retailers
who sells ones like this - redoing the brake lines is not an option, not yet anyway.....
[Edited on 14/8/06 by 02GF74]
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02GF74
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| posted on 14/8/06 at 11:19 AM |
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RESULT!!
First parts place could not identify it but asked quesnios like is it for Bendix, Girling ;
Ford's ruled out Fiesta as being too big, Allparts looked on system 22 mm bore matched up with 86-88 2.0l Sierra plus another which had
different spacing for bolt holes. (I could tell it was wrong by looking at the box!).
So there it is, £ 88 down on the day but.....
Quickie - how much clearance should there be between the puish rod and the pitson?
Thanks for repsonses
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MikeRJ
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| posted on 14/8/06 at 12:39 PM |
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quote:
Originally posted by CaLviNx
Hi All
not wanting to wee on anyone's chips here, but that don't look remotely like a RWD sierra master cylinder to me, its more like a FWD ford
affair from say a fiesta or a escort, the thing that gives it away is the fluid reservoir, look at its level line, this line shows the master cylinder
was intended to be fitted with its nose up at an angle,
Just checked my Sierra pedal box and the brake master cylinder is indeed mounted at an angle so that the reservoir is level.
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paulf
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| posted on 14/8/06 at 01:10 PM |
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Mine is also like that, the sierra and escort and fiestas are all the same, ive never seen a sierra master cylinder that is mounted level on the donor
car.
I actually mounted mine level in my car and it is not a problem in my opinion, neither did the SVA tester comment on it.
The fluid level switch still works correctly and the fluid level is full in both parts of the reservoir.
I wouldnt advise trying to repair one but at least it is easier to find a replacement if you have an idea of which car to look for one from.
Paul.
quote:
Originally posted by MikeRJ
quote:
Originally posted by CaLviNx
Hi All
not wanting to wee on anyone's chips here, but that don't look remotely like a RWD sierra master cylinder to me, its more like a FWD ford
affair from say a fiesta or a escort, the thing that gives it away is the fluid reservoir, look at its level line, this line shows the master cylinder
was intended to be fitted with its nose up at an angle,
Just checked my Sierra pedal box and the brake master cylinder is indeed mounted at an angle so that the reservoir is level.
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britishtrident
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| posted on 14/8/06 at 02:59 PM |
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You usually have to take the resevoir off to get the pistons on cylinders of this type a little stop peg under one or both of the resevoir rubber
grommet seals.
After that it is just a matter of pushing the outer piston in a bit so you can clean the crud out the end of the bore and then working the piston back
and forward a few times.
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James
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| posted on 14/8/06 at 03:17 PM |
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Looks just like one of the Sierra ones to me...
 
Sierra Master Cylinders
Top Girling one I suspect.
They're mounted on an angle in the Sierra but they work fine (horizontal) in my Locost that's just SVA'd!
To get it apart you need the reservoir off, and you pull out a small pin in one of the cylinders. The back then pops out.
If the fron then wont drop out, just tap the body lightly on your work bench and it'll appear eventually....
...usually accompanied by a load of fluid that spills over everything!
Cheers,
James
------------------------------------------------------------------------------------------------------------
"The fight is won or lost far away from witnesses, behind the lines, in the gym and out there on the road, long before I dance under those lights."
- Muhammad Ali
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02GF74
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| posted on 14/8/06 at 03:32 PM |
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Sorry James but I'm gonna have to hate you - I paid £ 88!!!
oh well, will have it together tonight at least.
about the old one, am wondering whether there is one pin to stop the primary psiton from pop[ping out (manual says it is for the secpondary - will
find out tonight).
just hope I don't bust the reservoir - just realised the one's you list come complete with this so I have to have you even more than when
I started this post.
(what is the linky? I hope they are cheap Britpart copies made from cheese )
[Edited on 14/8/06 by 02GF74]
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James
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| posted on 14/8/06 at 03:46 PM |
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quote:
Originally posted by 02GF74
Sorry James but I'm gonna have to hate you - I paid £ 88!!!
oh well, will have it together tonight at least.
about the old one, am wondering whether there is one pin to stop the primary psiton from pop[ping out (manual says it is for the secpondary - will
find out tonight).
just hope I don't bust the reservoir - just realised the one's you list come complete with this so I have to have you even more than when
I started this post.
(what is the linky? I hope they are cheap Britpart copies made from cheese )
[Edited on 14/8/06 by 02GF74]
Sorry mate!
You did post before 9AM and had bought it by 11:20!
Wasn't a lot of time for us to read your post!
That picture is from the Brakes International catalog.
If it makes you feel better they might well not have stocked it any more!
Take care with the reservoir. The connector pipes are (for want of a better word) barbed and really hard to get out..... and I found even bloody
harder to get back in!
Wiggle the reservoir side to side as to pull it/fit it. Make sure it's well lubed when you put it back in.
Hope that helps,
James
------------------------------------------------------------------------------------------------------------
"The fight is won or lost far away from witnesses, behind the lines, in the gym and out there on the road, long before I dance under those lights."
- Muhammad Ali
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Werner Van Loock
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| posted on 14/8/06 at 05:14 PM |
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I'm still looking for a suitable master cylinder, what's the url for the "Brakes International catalog"?
http://www.clubstylus.be
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James
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| posted on 15/8/06 at 12:06 AM |
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quote:
Originally posted by Werner Van Loock
I'm still looking for a suitable master cylinder, what's the url for the "Brakes International catalog"?
Google really is your friend:
http://www.brakesint.co.uk/
Cheers,
James
------------------------------------------------------------------------------------------------------------
"The fight is won or lost far away from witnesses, behind the lines, in the gym and out there on the road, long before I dance under those lights."
- Muhammad Ali
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NS Dev
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| posted on 15/8/06 at 12:25 PM |
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also bear in mind those prices are plus vat and plus delivery!
Retro RWD is the way forward...........automotive fabrication, car restoration, sheetmetal work, engine conversion
retro car restoration and tuning
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02GF74
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| posted on 15/8/06 at 02:14 PM |
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one end of the reservoir I managed to pop off using a chisel to wedge it upwards, other refusedto budge so I did as the manual said and pull by
leaning it to one side as opposed to straight up and out it came.
there is a pin to hold the seconday - hole for reservoir that is furtherst away.
I got the prinmary piston out using a rawl bolt - ecpanding cone jobbie - worked surprisingly effortlessly/
Insides look good but a have some brown stuff that doesnlt appear to be rust but some sort of varnish - that should clean up with no worries but since
I have a new one, might as well use that.
Progress is held up as I am going to fit an adjustable push rod - clevis from RD is on order so should be the w/end before all is back to where it was
the previous w/e
Will tidy up the garage in the meantime.
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jollygreengiant
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| posted on 18/8/06 at 02:44 AM |
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Just for information. That plastic tag wrapped around the master cylinder, under the reservoir is the Identification tag and you should use this to
identify the master cylinder. Also keep it for furture reference or fit to new cylinder.
Beware of the Goldfish in the tulip mines. The ONLY defence against them is smoking peanut butter sandwiches.
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02GF74
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| posted on 18/8/06 at 07:20 AM |
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quote:
Originally posted by jollygreengiant
Just for information. That plastic tag wrapped around the master cylinder, under the reservoir is the Identification tag and you should use this to
identify the master cylinder. Also keep it for furture reference or fit to new cylinder.
and bloody useful it is too - Ford couldn't make sense of it nor the two car parts places I took it too.
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