D2 Brake master cylinder repair kits

[OffTrack]

I picked up my first D2 (2000 TD5 Auto) a couple of days ago and today discovered the brake fluid level connector unplugged to disguise low fluid level resulting from a leaking fluid reservoir.

Plan "A" is to get the dealer to rectify this as a RWC issue. I'm not particularly confident this will get results so I'm looking for a Plan "B".

I've come across a part# SJJ100362 which is an overhaul kit which replaces the reservoir and seals and should fix my issue. These seem to go for around $85 which is a lot more manageable than $500 for a new master cylinder unit (a.k.a Plan "Z").

I'm curious if anyone had any experiences with this kit?

cheers
Paul

[justinc]

I picked up my first D2 (2000 TD5 Auto) a couple of days ago and today discovered the brake fluid level connector unplugged to disguise low fluid level resulting from a leaking fluid reservoir.

Plan "A" is to get the dealer to rectify this as a RWC issue. I'm not particularly confident this will get results so I'm looking for a Plan "B".

I've come across a part# SJJ100362 which is an overhaul kit which replaces the reservoir and seals and should fix my issue. These seem to go for around $85 which is a lot more manageable than $500 for a new master cylinder unit (a.k.a Plan "Z").

I'm curious if anyone had any experiences with this kit?

cheers
Paul

Paul, the plastic rear section will break off on the old one so I'm glad to see there is a new one in the kit. That is cheap too, last one I saw was over $110+ freight.

JC

[mattg]

I got a complete new master cylinder for about $220. It was a TWR brand. It has lucas stamped on the side just like the factory one. You will miss out on the Landrover stamp on the top of the plastic res. $380 for a stamp on the top. I got mine from MJK Discovery. worth shopping around. stay away from BritPart brake bits IMHO.

Cheers

Matt

[OffTrack]

I'm pretty sure that kit is Britparts or similar so perhaps not the best option. Not sure I'd trust my life to my brake overhaul skills - I reckon the last one I did was on a mini 20 years ago.

I've taken a look at the TRW cylinders and they seem like they might be a good option.
Thanks for the leads Matt.

cheers
Paul

[Psimpson7]

I've just had to put a new one in our 03 (I changed the slave aswell just to be sure)

Paddocks got me AP (original Equipment ones) for 79pounds and 22pounds respectively

(There are 4 different master cylinders for your info - early and late td5 and early and late v8)

Took 5 days to get here once they had found me an AP one (I told them I didn't want anything from Britpart/allmakes)

[OffTrack]

AP ceased to exist as a mass market brake component manufacturer in 2000 so it's going to be difficult to find AP master cylinders.

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The TRW part numbers for the TD5 RHD master cylinders are:

PNM220 - from chassis #3A000000
PMN221 - From chassis #.: XA232917 To Chassis #: 2A999999

According to the website of a local distributor Lucas products are being progressive rebadged as TRW.

cheers
Paul

[Psimpson7]

Indeed, I used to work only about 5 minutes from the AP factory.

Both the cylinders I took of our 2003 Disco have AP logos cast into them, as do the new ones that turned up earlier this week.

They are identical.

Maybe Delphi are making them with the same tooling now?

[OffTrack]

I asked Graeme Ulrich @ British Car Components in Nth Melbourne about master cylinders and he told me that in a lot of cases people are buying a whole master cylinder assembly when the problem is the leaking o-rings. His advice was that if your brakes are ok, and the fault is a leak is from between the reservoir and cylinder body the SJJ100362 kit at under $100 is the best option.

Apparently the kit contains parts required to replace the reservoir and o-rings, and isn't an overhaul kit for the cylinder itself. Maybe JustinC can weigh in as to whether the reservoir replacement can be done without removing the cylinder from the car?

cheers
Paul

[justinc]

I asked Graeme Ulrich @ British Car Components in Nth Melbourne about master cylinders and he told me that in a lot of cases people are buying a whole master cylinder assembly when the problem is the leaking o-rings. His advice was that if your brakes are ok, and the fault is a leak is from between the reservoir and cylinder body the SJJ100362 kit at under $100 is the best option.

Apparently the kit contains parts required to replace the reservoir and o-rings, and isn't an overhaul kit for the cylinder itself. Maybe JustinC can weigh in as to whether the reservoir replacement can be done without removing the cylinder from the car?

cheers
Paul

Paul, it can't, as there is a rolled pin through to the flange area that needs to come out, and the aforementioned plastic rear section has to come off and is very likely to break. I'd just get a new TRW one if I were you.

JC

[OffTrack]

Thanks Justin. Fortunately the dealer I purchased the car from has been pretty helpful and the D2 is booked in on Tuesday to have the master cylinder leak looked at.

cheers
Paul

[Psimpson7]

Ignore all my comments - I thought you were talking about the clutch one - clearly i cant read! sorry.

[OffTrack]

Geez, I wish the dealer had told me to fix the master cylinder myself!

I dropped the D2 off to the dealers designated mechanic at 8.00am Tuesday and I'm sitting here Saturday morning wondering when I'll have it parked in the drive next!!

The D2 sat in the workshop all Tuesday waiting for a replacement master cylinder which eventually turned up Wednesday afternoon.

After fitting the master cylinder and bleeding the brakes the car was test driven and on the way back to the workshop the brake pedal went hard. This was diagnosed as a fault brake booster. A replacement booster was ordered on Thursday and mechanics promised it would be there first thing Friday morning.

I rang them at 12.30pm only to be told "The booster hasn't turned up yet. I was going to call and find out where it was, I guess I should do that now..." FFS!!

Rang up at 4.30pm and was told they had just finished fitting, and to come down and pick up the D2. Got halfway there on the tram and the mobile went... they had problems - the brake pedal was still hard and they had no idea what the problem was so were pulling the booster and master cylinder apart again.

Anyway I'm so over this debacle I'm going to drop down and talk to them on Monday morning to see what the situation is and want to have an idea of what might be possible fixes/things they haven't tried.

I've done a bit of reading of various forum posts and have a number of potential causes for the hard pedal:


air in abs modulator - requires modulator bleed
leaking vacuum pump to brake servo hose - remove hose from servo and block end with motor running to check for leaks
missing o-ring between master cylinder and brake servo - I've seen one post mention that the o-ring was missing from replacement master cylinder and transferring the old o-ring solved the problem.


The brakes were fine apart from a slow leak from the brake fluid reservoir o-rings prior to the D2 being "fixed", so I'd guess the fault is direct consequence of replacing master cylinder.

Any suggestions?

cheers
Paul