Volkswagen Type II Transporter 1200 Series Shop Manual page 182

4-Brakes
( 4) Insert the main cup in the cylinder bore with the
lip of the cup towards the outlet end of the cylinder, taking
care that the cup lip is not turned back or damaged on
entry.
(5) Position the main cup in the bore so that the return
spring seat is located in the centre of the cup, instal the
piston washer against the face of the seal.
(6) Enter the piston and secondary cup into the bore
taking care not to turn back or damage the cup lip as it
enters the bore.
(7) Push the assembly in until it clears the end of the
master cylinder bore and instal the piston stop washer and
retaining ring. Ensure that the retaining ring is seated
correctly in the groove at the end of the bore.
(8) ·Using a new gasket instal the reservoir on the
master cylinder body.
NOTE: On the earlier models, ensure that the mark on the
bottom of the reservoir points to the stop lamp switch.
(9) Instal and tighten the stop lamp switch.
( 1 0) Instal the large end of the rubber boot over the
open end of the master cylinder and ensure that it seats
correctly.
( 11) Insert the push rod through the boot and engage
the end in the piston bore, the adjusting nut should be
inside the rubber boot with the hole of the boot seated on
the plain part of the push rod.
(12) Pour a small quantity of clean hydraulic fluid in
the reservoir and pump the push rod until fluid begins to
emerge from the cylinder outlet. '
TO REMOVE AND INSTAL (Dual Circuit)
(1) Raise the vehicle on a lift or place over a pit.
(2) Disconnect the hydraulic brake pipes to the front
and rear brakes and drain the fluid from the master cylinder
and fluid reservoir into a suitable container.
(3) Take out the master cylinder securing bolts and
withdraw the master cylinder from the end of the push rod.
Installation is a reversal of the removal procedure with
special attention to the following points:
(1) Instal the master cylinder, locating the small end of
the rubber boot over the push rod.
(2) Fit and tighten the master cylinder securing bolts.
(3) Connect the hydraulic pipes and tighten securely.
( 4) Reflll the fluid reservoir and bleed the system in
the normal way.
TO DISMANTLE (Dual Circuit)
(1) Remove the master cylinder rubber boot and the
stop screw for the front brake piston and spring assembly.
(2) Take out the spring ring and stop washer from the
open end of the master cylinder and withdraw the rear
circuit piston with washer and primary cup, the support
· washer, spring guide and rear circuit piston return spring,
stop sleeve and stroke limiting screw as an assembly.
(3) Withdraw the front circuit piston, secondary cup ·
and seal assembly with primary cup and washer' support
washer and front circuit piston return spring and guide
plate.
( 4) If necessary, unscrew and remove the three outlet
unions and seals containing the residual pressure· check
valves.
TO CLEAN AND INSPECT
· (1) Tho~oughly clean the ~aster cylinder components
and the inside of the mastercylinder bore with methylated
spirits. Do not use petrol or other mineral spirits.·
PLASTIC FLUID RESERVOIR
/ MASTER CYLINDER BODY
PISTON AND RETAINER
SUPPORT SECONDARY SPRING
SPRING PRIMAR't' SECONDARY RETURN SPRING WASHER CUP
1
RETURN SPRING GU1.DE
cvp ..
C~.
p
STROKE LIMITING (REAR) .
t .
.l..
·Mt\.
fi
J
~
~OrJ··':~~';Z.,. ~~t~i~r
t
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STOP SLEEVE SPRING PRIMARY RETAINER
SUPPORT WASHER CIRCUIT SEAL GUIDE CUP . WASHER
PISTON WASHER
ADJUSTABLE PUSHROD
RUBBER BOOT
Components of Master Cylinder Dual Circuit Type.
182