Replacing the brake master cylinder

[DaveKennedy]

Hello all

I need to replace the brake master cylinder on my left hand drive 1962 Series 3. (The brake pedal sinks slowly under pressure.)

Getting it out looks very difficult. Has anyone done this job on a LHD car?
If so can you give me any tips on what order to remove things and any special tools needed?

Looks like it's best taken out from underneath but maybe I should remove the manifold and front-pipe anyway to get better access.

Would appreciate any suggestions.

Dave

[lancianut666]

I would be tempted to leave the fluid reservoir connected and strip it all down on the bench if possible. I you could get the car up on ramps it would be a help. It might be easier to do than you think as from memory it is held in by 2/3 bolts.
Clarkey

[simonandjuliet]

I'm afraid it's not a nice job on a LHD car !

Definitely done from underneath and from memory, best to remove as many things as possible to give you some room. I don't recall disconnecting the gear linkage, but I did take off the exhaust and brackets

Re-fitting was done by connecting everything loosely (reservoir pipe, unions etc) before bolting to the chassis, and once it was all in place then tightening up

No special tools needed , but double jointed, small hands would be helpful

[DaveKennedy]

Many thanks for the encouragement and helpful suggestions. The reservoir has sealant on it where I guess leaked in the past and I have a spare so I'll change that too.

I can't start the job for a couple of weeks so I'll get things ready and report back later.

[lancianut666]

The Consortium might have a seal set if you need one.

[lancianut666]

For the reservoir...

[DaveKennedy]

Thanks Jim. I'll email you next week.

[Spider2]

yep, done it on a LHD Series 2. Definitely a PITA job. What helped was :
1/Remove generator
2/ Remove LH wheel because there is an access panel in LH wheel arch for viewing
3/ Remove drivers side carpets and the plate that secures the accelerator shaft to the floor. This also gives good viewing access.
4/ Remove starter, but this is just as difficult
5/ Remove brake light switch wires and move cable out of the way
5/ Keep reservoir attached and remove cylinder with reservoir attached.
Now it just finding the correct size/length/thickness of spanners
6/ Find the antiseptic and band aids for the grazed knuckles
7/ Open a cold beer and relax
Note 6/ and 7/ may be reversed depending on the severity of bleeding.
Just renewed the exhaust manifold gasket and if above is 8 on the difficulty scale the gasket renewal was 9 or 10.
The Appia is a lovely car but Lancia did not make it easy to work on
 

[DaveKennedy]

Many thanks for that. Several points there I hadn't thought of. The cold beer will be very important!
There's absolutely no way I can remove the starter. I've looked at that before.
I'll remove the front exhaust pipe and the generator.

Keeping the reservoir attached there are still two unions to undo on the top of the cylinder which look unreachable but hopefully the cylinder will move up a bit to allow better access.

Slight damage to a back muscle at the moment but when it stops hurting I'll get started .....

[nistri]

Right, very difficult job. The Appia was designed to be RHD. Thus, anything moved to the other side becomes a major hassle. I have removed and replaced the starter motor with patience and cursing.

[Spider2]

Give us the blow by blow, curse by curse, official way of replacing the starter motor because I think Lancia were so embarrassed about the virtual impossibility of the task that they dare not mention it. 

[nistri]

It helps to move the engine a bit.

[Spider2]

Yes, I think lifting the engine helps with quite a few tricky jobs. I have just replaced the exhaust manifold gasket and getting it off was a nightmare as I did not lift the engine enough as I was afraid of loosening the engine mounts too much because the bottom half of the mount is spring loaded and I feared it all flying apart. I did loosen off the mounts more on replacing the manifold and it made the job quite easy.
One of the next jobs on my list is rebushing the gear change linkage. I hear this is quite challenging, perhaps I should have done it with the manifold off and the exhaust pipe dropped down  Anyone done this job?

[simonandjuliet]

"One of the next jobs on my list is rebushing the gear change linkage. I hear this is quite challenging, perhaps I should have done it with the manifold off and the exhaust pipe dropped down  Anyone done this job?"



Yes but with the engine & 'box out !

[DaveKennedy]

There wee no rubber bushes in the gear change linkages when I got my car.  I fitted them when I had the gearbox out, so at that time the exhaust pipe was off but the manifold was still on.
Can't remember the details but I don't think it was difficult.