Sunbeam ALPINE I SERIES: APLINE II SERIES, Workshop Manual

Page: 274 / 413

WSM.124
Section K (Brakes)
4th re-issue
Pa1e 15
ALPINE
Remove the master cylinder from the bulkhead by
easing It forward. Note the position of the packing.
To refit
Refitting is a reversal of the above instructions.
Care should be taken not to over-tighten the
pipe unions. (See under "Maintenance" for torque
figures).
After refitting, the brakes should be bled as des­
cribed under "Bleeding the system".
To dismantle (See Fig. 8)
Remove the master cylinder from the car as
pre­
vlously described.
Clean off all dirt and grease from the outside of the
master cylinder.
Drain the residue fluid from the pressure cylinder
and reservoir Into a suitable container.
Depress and withdraw return spring cap to release
return spring.
Pull back the rubber dust cover (10).
Remove the circlip (9) with a pair of long nosed
pliers thus releasing the push rod and dished
washer (13).
When the push rod assembly (13) has been removed,
the end of the plunger (8) will be exposed. Remove
the plunger (8); this operation can be simplified by
Inserting a low pressure air nozzle in the fluid
outlet port.
Separate the thimble (11) and return spring (6) from
the plunger (8) by levering the thimble leaf over
the shouldered end of the plunger.
Depress the plunger return spring (6) and slide the
valve stem (7) through the elongated hole of the
thimble and withdraw. Remove valve spacer (5).
Take care not to lose the spacer spring washer (5)
which is located under the valve head.
Remove seals (12, 14, and 4) from t�e plunger and
the valve head. Seal (14) Is omitted from later
master cylinders.
Examine all parts, especially the seals, for
wear
or
distortion and replace with new parts where
necessary.
To reassemble (See Fig. 8)
It Is essential that all internal parts are meticulously
cleaned with brake fluid before reassembly. Do not
use petrol, paraffin, trlchlorethylene or
any other
similar agents to wash the parts.
Replace the valve seal (4) sc that the flat side Is
correctly seated on the valve head with Its lip facing
outwards. The spring washer (5) should then be
located with the dome side against the underside of
the valve head, and held In position by the valve
spacer, the legs of which face towards the valve seal.
Replace the plunger return spring (6) on the spacer
(3). Insert the thimble (11) Into the spring and
depress until the valve stem (7) engages through
the elongated hole of the thimble, making sure
that
the stem is correctly located In the centre of
the
thimble. Also check that the return spring Is
placed centrally on the spacer.
Refit plunger seals (12 and 14) onto the plunger (8)
with the projecting lips facing towards the thimble.
(See
Inset). Seal (14) Is omitted from later master
cylinders.
Insert the reduced end of the plunger (8) Into
the
thimble (11) until the thimble engages under the
shoulder of the plunger. Press home the thimble
leaf.
Smear the plunger (8) well with rubber-proof grease
(red) and Insert the assembly Into the bore of the
cylinder (1), valve end first, easing the plunger seal
lips over the edge of the bore.
Refit the push rod assembly (13) to the cylinder
securing It with the circllp (9) which should engage
into the groove machined In the cylinder bore.
Refit the rubber dust cover (10) Into position by
stretching it over the end of the barrel.
Refit return spring and return spring cap.
Refit the master cylinder to the car as previously
described.
FLEXIBLE HOSES
Do not attempt to clear the bore of a flexible hose
by probing. If a hose Is choked or perished, fit a
replacement.