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There is an easy way and a difficult
way to remove the master cylinder.
The difficult way is to follow the manual which
tells you to remove the torsion bar.
The easy
way is as follows:
Remove the master cylinder floor cover.
Slacken the brake pipe tube nut, but DO NOT remove
it completely.
Undo the banjo bolt from the rear of the master
cylinder. It will work its way up the tube nut
thread. When the two lock together, slacken the
tube nut a little further, but still dont
remove it completely. Continue this process until
the banjo bolt is out of the master cylinder.
Remove the nuts from both master cylinder bolts.
Using a large flat blade screwdriver under the
head of one of the bolts, lever the torsion bar
down. Remove the other bolt.
Using a large cross head screwdriver in the hole
left by the removed bolt, lever the torsion bar
down and remove the other bolt.
Assembly is a reversal of the above.
Unfortunately, not all cars allow
the use of the above method. Build tolerances,
particularly on later models, were not always
as good as they should have been!
With this in
mind, we have included the following from Peter
Jones of Liverpool:
When I renewed
my master cylinder I found it impossible to use
a lever under one of the bolt heads to displace
the torsion bar sufficiently to remove the other
bolt. What I did, and found very easy, was to
use a piece of chain around the torsion bar, of
a size to fit between the chassis and torsion
bar, and hanging down a short distance below the
chassis. The chain may be joined using a suitable
small shackle. Hold a piece of wood against the
underside of the chassis then using the wood as
a leverage point and the chain as a fulcrum, place
a strong bar through the chain and under the wood
and lever the torsion bar down to enable removal
of both bolts. Two or three small shackles can
be used instead of the chain. To make it easier
next time!!! refit the bolts with their heads
towards the middle of the car.
(Note
from DSN Classics: We would not normally recommend
the reversal of the bolts. However, if you you
are absolutely sure that the clearance is sufficient,
then it should be OK. The problem relates to build
tolerances as mentioned above! )
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