Volkswagen Type II Transporter 1200 Series Shop Manual page 183

(2) Check the inside of the bore for \\;'ear and/or
pitting. If necessary, gently hone the cylinder bore.
(3) Check the condition of the rubber cups, seals and
rubber boot and reriew if perished, deteriorated or
damage
ct.
(4) Ensure that the compensating ports in the cylinder
are free from any obstruction.
TO ASSEMBLE (Dual Circuit)
(1) Lubricate all the hydraulic brake components with
clean hydraulic fluid.
{2) Instal a new secondary cup and rubber seal on the
front circuit piston; so that the lipped edge of the cup is
toward the spigot end of the piston.
(3) Place the cup washer, primary cup (lipped edge
forward), support washer, spring guide plate and spring on
the spigot end of the front circuit piston.
(4) Insert the forward piston, so assembled, into the
cylinder bore and push it down until the spring contacts the
blind end of the cylinder bore. Ensure that the lip.s of the
primary and secondary cups are not turned back or
damaged.
(5) Instal a new secondary cup in the groove in the
main piston so that the lipped edge of the cup is to the
spigot end of the piston.
{6) Place the cup washer, primary cup, support washer,
guide plate, stop sleeve, spring and stroke limiting screw on
the spigot end of the main piston and insert the main piston
assembly into the cylinder bore, taking care not to turn
back or damage the lip of the primary or secondary cup.
{7)
Push the main piston down the cylinder bore,
position the stop washer arid instal the retaining spring clip.
Brakes-5
Brake Pipe Junction with ::itop Light Switch for each
Circuit. Dual Circuit System.
(8) Push the main piston down the· master cylinder
bore and instal the front brake circuit piston stop screw and
washer in the cylinder body.
{9) Instal the pipe union and check valve assemblies
and seals and tighten securely.
{1 0) Instal the rubber boot over the open end of the
master cylinder.
:J. FRONT BR.~KE ASSI<~MBLY
TO REMOVE BRAKE SHOES
{1) Raise the front of the vehicle and support on
stands.
{2) Take out the split pin retaining the speedci cable in
the left front hub cap and withdraw the cable rearwards
from the steering knuckle.
{3) Remove the front hub caps, loosen and remove the
hub assembly securing nut and locking assembiy, draw the ·
brake drum and hub assembly from the stub axle.
NOTE: Refer to FRONT SUSPENSION- TO REMOVE
AND INSTAL FRONT HUBS for description of operation
( 3) which differs on some models.
It may be necessary to back off each brake shoe from
183
the drum at the toothed adjusting nuts in order to facilitate
removal of the assembly.
( 4) Mark each shoe for correct assembly, using a
screwdriver as a lever, ease each end of the brake shoes out
of the slots in the adjusting screws taking care not to
damage the leaf spring on the adjuster.
(5) Remove the shoe assemblies from the back plate, if
necessary unhook the return springs from the shoes:
TO REMOVE WHEEL CYLINDERS AND BACKPLATE
{1) Carry out the procedure previously described to
remove the brake shoes.
(2) Loosen off the brake line union at the support