SAFARI

1344 / 1526

8
CLUTCH
9. MASTER CYLINDER
9A. DISMANTLING OF MASTER CYLINDER (Fig. 6)
l Pull back dust cover. (14)
l Remove circlip retaining push rod (12)
l Remove push rod with retaining washer (11)
l Remove plunger (10) and valve assembly from
body by lightly tapping the body on wooden
block.
l Using a screw driver, lift the leaf of spring retainer
(8). Remove spring assembly from plunger.
l Compress spring (6) to free valve stem (7) from
eccentrically positioned hole in the end face of
spring retainer. This will separate spring retainer
from valve stem.
l Remove spring, valve spacer (5) and spring washer
(4) from valve stem.
l Carefully remove valve seal (3) from valve stem.
l Carefully remove gland seal (9) from plunger.
9B. INSPECTION AND ASSEMBLY OF MASTER
CYLINDER (Fig. 6)
l Examine bore of body. If it is not scored, ridged or
corroded, do not replace. If there is damage in the
bore, the cylinder assembly should be replaced.
Even otherwise if the clearance between plunger
and the bore exceeds 0.13 mm, the assembly
should be replaced.
l Examine plunger for rust, burrs and ridges,
Replace if necessary.
l Fit new gland seal on plunger such that it fits
squarely in plunger groove.
l Fit new valve seal on valve stem with the smallest
diameter leading.
l Assemble spring washer on valve stem such that
it bends away from valve shoulder.
l Now assemble valve spacer on valve stem. Hold
the spacer between fingers such that the valve
stem hangs down vertically. Pull the stem
downwards as far as possible. Release the stem.
Observe whether the valve stem has moved freely
upwards. If movement is not free replace valve
spacer.
l Install spring over valve stem behind valve spacer,
followed by spring retainer. Compress spring and
locate valve stem end in key hole slot of spring
retainer.
l Fit spring assembly on plunger assembly and lock
the leaf of spring retainer by pressing it with nose
pliers.
l Lubricate bore of body with brake fluid and dip
plunger valve assembly in it. Insert the assembly
into bore with valve end leading.
l Check condition of dust cover. If necessary replace.
l If disturbed, adjust push rod length with fork to
specified value.
l Place push rod with retaining washer on plunger
and fit circlip for retaining push rod in the body
groove.
l Fit dust cover on body.
10. SLAVE CYLINDER
10A. DISMANTLING OF SLAVE CYLINDER (Fig.7)
l Remove circlip (4) and washer (2).
l Remove dust cover (3).
l Remove plunger (5) with gland seals and plunger
spring (7) from body by lightly tapping it on
wooden block.
l Remove gland seals from plunger.
10B. INSPECTION AND ASSEMBLY OF SLAVE
CYLINDER (Fig.7)
l Examine bore of body. If it is not score, ridged or
corroded do not replace. If there is doubt about
condition of bore, then it should be replaced with
new slave cylinder assembly. Even otherwise if the
clearance between the plunger & bore exceeds
0.13 mm. the assembly should be replaced.
l Examine plunger for rust, burrs, and ridges,
Replace if necessary.
l Fit new gland seals on plunger such that it fits
squarely in plunger groove.
l Fit small end diameter of spring to plunger.
l Lubricate bore of body with brake fluid and dip
plunger assembly in it. Insert plunger assembly
into bore with bigger end diameter of spring
leading.
l Fit washer over push rod and place it over plunger
as shown. Fit circlip.
l Check condition of dust cover. If necessary
replace.
l Slide dust cover over body.
l Ensure the push rod length from the slave
cylinder mounting face is as shown in sketch.