31 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)
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