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Old 07-11-2007, 12:44 PM   #11 (permalink)
smcurro
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Join Date: Jul 2007
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The gasket diaphram under the cover of the master cylinder is very important, not only does it keep water from getting in, but it keeps brake fluid from getting out! A snug fit is essential otherwise a seemingly correct master cylinder cover can still leak. I know from experience! On the older all steel master cylinders it is a good idea to remove the wire from the cylinder and gently bend it in order to make a tighter fit if the fit is not tight already. It should not be able to be unclipped by hand. A loose cover can not only allow brake fluid to make a mess of the master cylinder and brake booster/firewall, but it can potentially allow air into the brake lines and compromise the brakes if neglected long enough. Upon covering the master cylinder for the long run, the gasket and corresponding surfaces should be made very clean and free of any rust and dirt to insure a good seal. Be careful when cleaning the master cylinder and make sure not to drop any dirt into the brake fluid. The best time to clean the master cylinder gasket edge is right out of the box before it is installed. Even brand new these surfaces can be cruddy and uneven, especially on older all steel master cylinders. Brake fluid strips paint and my freshly painted brake booster was ruined due to this leaky seal - I had to take it out again and repaint it!
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