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SS100 Build Manual (Export Edition)
4.4
Braking system & clutch hydraulics.
You will need the following parts for this operation:
Foot pedals & cross shaft.
•
Brake master cylinder, servo unit and clevis/split pin.
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8mm ID x 12mm spacers – supplied with servo (4).
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Servo vacuum non-return valve from donor car, this is sometimes built in the servo elbow.
•
Clutch master cylinder, actuating rod & clevis/split pin.
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Front brake flexible hoses (2) with locknuts (4) and shake proof washers (4).
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Clutch flexible hose with locknut.
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Set of 3/16" OD brake pipes, ready flared and fitted with unions (see appendix 7).
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3/16" OD clutch hydraulic line.
•
•
3/8"UNF "T" piece union with female threads (1).
3/8"UNF 4 way union with female threads (1).
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Brake light switch - 3/8"UNF male thread.
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M8 nyloc nuts (4).
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5/16"UNF x 1" bolts & nyloc nuts (6).
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4mm split pins (2 off).
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Suitable washer to fit on the cross shaft.
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3/16" "P" clips (12).
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No6 x 1/2" self-tapping screws (20).
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1/4"UNF x 1" set screws (2).
•
Important safety note: The components in the hydraulic circuit have a mix of metric and imperial tube
connections. The brake master cylinder and most late XJ6 front calipers use M10 x 1.0 mm pitch threads.
The unions, tee pieces and hoses are generally imperial and use 3/8" UNF threads. The rear calipers likewise
are imperial and use 3/8" UNF threads. Take care to ensure that the correct fittings are used. The metric and
imperial threads are very similar. (3/8" UNF is 9.6 mm x 0.94mm pitch). Metric unions are generally gold in
colour and imperial silver.
Refer to appendix 7 for brake pipe union sizes and locations.
4.4.1 Pedals
Assemble the foot pedal tops to the arms with 4 of 5/16" x 1" bolts & nyloc nuts (imagine they are fitted in
the car and fit them to the outside of the pedal arms, this will give maximum room for pedal use), and locate
them in the chassis using the hollow cross shaft. When positioned correctly, the hole in the chassis should
line up with the hole in the pivot shaft this can be secured with a 4mm split pin or bolt. Fit the washer on the
cross shaft to retain the pedals in position. Mark the appropriate position of the washer, remove the cross
shaft and drill a hole for the other 4mm split pin. Reassemble the shaft with the washer and split pin. If the
pedals are too loose, adjust or fit another washer to rectify this, the pedals need to be loose enough to move
but not to tight they stick.
4.4.2 Brake master cylinder and servo
Install the servo using the drilled plate in the chassis placing the 8mm ID x 12mm spacers between the servo
unit and the plate. Make sure the top studs do not stick through too far and catch the pedals when depressed
fully, if they do remove the servo and shorten accordingly before securing with the 4 M8 nyloc nuts. Attach
the master cylinder rod to the brake pedal with the clevis pin and split pin provided. When fitting the
floorboards you need to check access to the split pin for maintenance. When happy grease the inside of the
master cylinder where the servo pin pushes on the piston before bolting into place.
4.4.3 Clutch master cylinder
Bolt the clutch master cylinder to the flange in the chassis using 2 of 5/16"UNF x 1" bolts & nyloc nuts.
Connect the master cylinder rod to the clutch pedal with the actuating rod, clevis pin & split pin with the
actuating rod screwed on to the master cylinder rod to give a satisfactory piston stroke when operating the
Page 24
Rev 10 November 2013
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