SAFARI

BRAKES

ASSEMBLING TANDEMMASTERCYLINDER

(Fig.32)

Absolute cleanliness has to be maintained and clean

fresh brake fluid must be used. Never use the brake

fluid bled from the system as it is aerated.

To facilitate easy assembly, smear the cylinder bore

with fresh brake fluid liberally. Dip the plungers and all

seals in fresh brake fluid. Fit the recuperating seals in

the secondary plunger grooves.The first seal lip facing

the primary plunger assembly and the lip of the second

seal facing the opposite side. Push the seal shim,

recuperating seal on the stem side of the secondary

plunger in such a way that the lip of the seal faces

towards the secondary spring. Fit the spring retainer

in correct position and fit the secondary spring.

Clamp the cylinder body with its mouth pointing

upwards in a vice fitted with soft jaws. Fit secondary

plunger assembly with the secondary spring leading

into the bore using seal guide. Then slowly push the

plunger down the bore, with a round ended rod. Press

it down fully and whilst holding screw in the stop pin

with a new gasket (stop pin) and tighten to a torque of

0.7 - 0.55 mkg. Slowly let the secondary plunger back

till it touches the stop screw.

Now insert the primary plunger assembly in the same

manner into the bore using the seal guide.

Fit the first stop washer on to the primary plunger

shaft. Fit the primary back seal into bush and slide

the bush on to the primary plunger shaft with the seal

in the bush leading into the bore. Now press the bush

firmly into the bore.Now insert guide on to the primary

shaft.Whilst pressing down the guide remove the bush.

Remove the guide from the primary plunger shaft.

Insert intermediate ring on to the primary plunger shaft.

Fit the second primary back seal into Bush and fit the

seal on to the primary plunger shaft as done earlier.

Fit the second stop washer on to the plunger shaft.

Now fit circlip by using a circlip plier.

1. BODY

2. GASKET

3. STOP PIN

4. GREASE TUBE

5. SEAL FLUID TANK

6. 'O' RING

7. SPRINGSECONDARY

8. SPRING RETAINER

9. RECUPERATING SEAL

10. SEAL SHIM

11. SECONDARYPLUNGER

12. BACKSEAL

13. PRIMARY PLUNGER ASSEMBLY

14. STOPWASHER

15. SEAL

16. RING

17. CIRCLIP

Fig. 32 - Tandem master cylinder - Exploded view (Non ABS)