B42.10-0418-09
1 Hydraulic master brake cylinder
2 Connection holes of the braking lines
3 Hole for connecting the braking line with the protective cap (indicated by the arrow) installed
4 Plastic connections to connect the brake fluid tank lines. (Repair)
5 Sealing rings for the plastic connections. (Repair)
6 Sealing ring (annular) for the fitting of the master cylinder to the servo-brake. (Repair)
7 Rod to fit the master cylinder to the servo-brake
8 Piston return spring. (Repair)
9 Spring limiting part, see mounting position. (Repair)
10 Primary piston. (Repair)
11 Front gasket, note the installation position. (Repair)
12 Rear gasket, note the installation position. (Repair)
13 Secondary piston, full, including rod, valve (A), gasket and spring (B) to form a single assembly (Supplied complete for repair)
14 Thrust washer. (Repair)
15 Sealing ring mounted inside the housing part (16). (Repair)
16 Housing part for the sealing rings of the rod of the secondary piston assembly (14). (Repair)
17 Sealing ring mounted outside the housing part (16). (Repair)
18 Elastic locking ring. (Repair)
A Valve with gasket (included in the secondary piston)
B Spring of the secondary piston (included in the secondary piston)
| Important preliminary information | ||
All recommended precautions should be observed at all times, both for personal safety to avoid accidents and for environment protection | |||
1 | Place the vehicle on a flat, level location to enable safe working conditions. Place chocks on the rear wheels to prevent it from accidentally moving. In this case, using a lift for this operation is not necessary | ||
2 | The master cylinder can be removed and installed from the brake booster mounted on the pedal assembly; however, depending on the situation, as a rule, removing the entire pedal assembly from the vehicle may be more convenient | ||
3 | Turn off the main switch | Since the vehicles are electronic, always follow the recommendations for this type of vehicle. | |
| Remove from the primary holder the brake pedal assembly with the brake booster and the master cylinder mounted | ||
4 | To remove the complete assembly, or if repairs or adjustments are required in the brake pedal components, please refer to: Removing and installing the brake pedal. | ||
5 | Remove the steering column cover to make the access to the pedal assembly easier | Refer to: Removing and installing the steering column. | |
Danger! | Safety instructions for the brake fluid | ||
6 | Protect the bottom of the cabin against brake fluid spills. Due to the location of the fluid reservoir and other components of the brake under the dashboard, certain precautions are required | ||
Properly line the bottom of the cabin, because even with great care, brake fluid can be spilled, causing damage to the paint or other components. | |||
7 | Empty the entire system depression (vacuum) by continuously pumping on the brake pedal with the engine off. Then, empty the brake system fluid | A puring device may be used. See for reference: Purge the air from the brake system. | |
8 | Disconnect the brake light switch wiring The supply hoses to the master cylinder should be carefully removed from the connections (4) mounted on the master cylinder (1) Carefully disconnect the line (2) and (3) from the master cylinder. Plug the ends of the lines to prevent the brake fluid from spilling | Be careful with the brake fluid reservoir. Plastic connections (4) fitted in the master cylinder (1) will be removed later. Disengage both hoses from the connections (4). Plugging each end of the lines with a small plug to prevent brake fluid spills. | |
Mount the empty line under the dashboard with all outlets protected | |||
9 | Remove the collar screws that secure the assembly bracket onto the primary steering support and remove it completely from the vehicle | The brake pedal assembly will come out complete with the brackets, the brake booster and the master cylinder (1). | |
10 | Secure the assembly on an appropriate base that enables disassembling and re-assembling the master cylinder (1) | ||
11 | Remove both nuts securing the master cylinder (1) onto the brake booster and carefully pull out the master cylinder (1) | If you still hear a depression (vacuum) inside the brake booster, removing the master cylinder will be difficult. Pay close attention to the master cylinder connection to the brake booster. Disassembling or assembling without due care may damage both, causing serious losses. Therefore,close attention is required. | |
| Disassemble the master cylinder repair | Watch the correct position of the internal components of the master cylinder. | |
12 | Remove from the front the snap ring (18), the housing part (16) with the O-rings (15) and (17). Remove the thrust washer (14) and secondary piston (13) complete with the valve (A) and the spring (B) | When disassembling, watch the positioning of the housing part (16) with the sealing rings (15) and (17) so that the new ones are mounted the same position. | |
13 | Remove the piston (10) complete with the gaskets (11), (12) and the spring limiting part (9) | When disassembling, watch the position of the limiting part (9) and the spring (8). | |
14 | Remove the plastic connections (4) and the respective sealing rings (5). Remove the sealing ring (6) from the external connection of the master cylinder | The components removed from the master cylinder insteps 12; 13 and 14e, as well as the brake fluid, should be disposed of in compliance with the environmental standards. | |
| Check | ||
15 | Inspect the internal conditions of the master cylinder. If it shows wear or rust, it should be replaced | The master cylinder should not be burnished or ground. However, as thin a wet sandpaper as possible may be used if internal residues are found. | |
| Clean the master cylinder | ||
16 | Thoroughly clean the master cylinder body both inside and outside | The master cylinder should be washed with clean brake fluid or hydrous ethanol (pharmacy alcohol). Petroleum products such as gasoline, kerosene or diesel fuel damage the rubber components. When drying, use clean, dry compressed air and special lint-free, thin flannel cloth. | |
| Assemble the repair components | ||
17 | The mounting rod (7) of the master cylinder should be in perfect condition to be mounted on the brake booster. Mounting it in a vise without due care may cause serious damage, rendering the cylinder unusable All internal components of the master cylinder are new, since these are included in the repair supplied | All components for the necessary repair should be lubricated with clean, specified brake fluid. | |
18 | We recommend closing with appropriate caps the holes (2) and (3) on the master cylinder (1) to prevent dirt from getting inside | ||
19 | Mount the sealing ring (6) and the rings for the connections (5) with the respective connections (4) on the master cylinder (1) | ||
20 | Validate that the inner part is perfectly clean and mount in the correct position the assembled internal piston assembly, including the return spring (8), the limiting part (9) and the piston (10) with gaskets (11) and (12) mounted | ||
21 | Install on the guide of the secondary piston (13) a thrust washer (14), the sliding piece (16) with the sealing rings (15) and (17) mounted Mount the secondary piston assembly on the master cylinder (1). Mount the snap ring (18) | The secondary piston (13) assembly consists of a spring (B) and a valve (A) with a gasket. These components are integral parts of the piston, and should not be disassembled. | |
| Preparation and assembly of the master cylinder on the brake booster | To install the master cylinder (1) on the brake booster, much attention is necessary because if the master cylinder is not well centered in the socket at the actuating center, both the brake booster and the cylinder will be damaged. | |
22 | Before starting the assembly of the master cylinder, watch the position of the rod inside the brake booster: The rod inside the brake booster should be perfectly seated in its housing Looking from the brake booster window, the rod should be secured and aligned with the center of the window | ||
23 | Horizontally and very carefully, mount the master cylinder on the brake booster, so that the brake booster rod fits into the piston bore of the master cylinder | The position of the rod and the master cylinder direction ensure the proper fit; otherwise, the assembly may be damaged. | |
24 | If the fitting is perfect, mount both nuts and tighten these evenly, fastening the flange of the master cylinder to the brake booster | ||
25 | Tighten both nuts to the specified torque | The specified torque is extremely important for the operation of the assembly, so a calibrated torque wrench should be used. | |
| Mount the brake pedal assembly complete with the brake booster and the master cylinder on the primary holder, and connect the lines | Refer to: Disassembling and assembling the brake pedal. | |
26 | Fill the system with brake fluid and purge Check for any signs of leakage through the line connections and, in this case, make the appropriate corrections | Use a purging device. See for reference: Purge the air from the brake system. | |
27 | Install the steering column cover | Refer to: Removing and installing the steering column. | |
28 | Check that everything is in order, remove the protection from the cab floor, turn the main switch on and perform a test drive |
Pedals, bearing bracket
Número | Denominação | Vehicles 979.013/ 016 | |||
BA29.10-B-1008-02C | Nuts attaching the master cylinder to the servo-brake. | Nm | 25 | ||
Produtos para reparos
Número | Denominação | Número de pedido |
BR00.45-B-1011-06A | Brake fluid as per DBL 7760.30 (DOT 4) | - |