Range Rover Classic. Manual — part 124
BRAKES
3
REPAIR
Repair
WARNING: Use only unused brake fluid to
clean any part of brake system. DO NOT
use petrol, kerosene or other mineral
based fluids.
7. Thoroughly clean master cylinder and inspect
outer surfaces for damage and condition, renew
complete assembly if necessary.
8. Using two soft jaws, clamp master cylinder
flange in a suitable vice. Remove water ingress
’O’ ring seal from master cylinder to servo flange
and discard.
9. Grip outside of transfer housing with a suitable
pair of pliers, carefully pull, working pliers in a
backwards and forwards rocking motion to ease
housing off master cylinder. Discard housing and
vacuum seal.
70
BRAKES
4
REPAIR
10. Ease reservoir out of master cylinder taking care
to ensure that two outlet ports on bottom of
reservoir do not become damaged during this
process.
11. Withdraw two reservoir seals from master
cylinder inlet ports. Note for reassembly these
seals are different. Discard seals.
12. Remove retaining ring and ’O’ ring seal from
machined outer surface of master cylinder.
Discard both seal and retaining ring.
BRAKES
5
REPAIR
13. Remove guide ring, which supports primary
plunger assembly, from mouth of master
cylinder. Place to one side for reassembly, note
this component is not part of service kit.
14. Pull primary plunger assembly out of master
cylinder.
NOTE: The primary plunger assembly
cannot be broken down any further and is
serviced as a complete unit. Discard
assembly.
15. The secondary plunger assembly will remain at
bottom of master cylinder bore. Remove, tapping
assembly on a piece of wood until plunger
appears at cylinder mouth, carefully pull plunger
out of master cylinder.
16. If swirl tube was not expelled at same time as
secondary plunger, repeat above operation to
remove it from bottom of master cylinder bore
and discard.
17. Clean all parts with unused brake fluid. Place
cleaned parts onto a clean sheet of paper.
Inspect cylinder bore and plungers for signs of
corrosion, ridges and score marks. Provided
working surfaces are in perfect condition, new
seals from a Girling Service repair kit may be
used.
Renewing secondary plunger seals
18. Remove following components from secondary
plunger and discard:
NOTE: A small screwdriver with end
rounded off and polished is required to
remove ’L’ seal. DO NOT damage
secondary plunger.
(A) Springs
(B) Seal retainer
(C) Recuperating seal (primary cup)
(D) Washer
(E) ’L’ seal
70
BRAKES
6
REPAIR
MASTER CYLINDER ASSEMBLY
Key to master cylinder
1. Water ingress seal
2. Transfer housing
3. Vacuum seal
4. Guide ring
5. Retaining ring
6. ’O’ ring seal
7. Primary plunger assembly
8. ’L’ seal
9. Secondary plunger
10. Washer
11. Recuperating seal (primary
cup)
12. Seal retainer
13. Springs (2 off)
14. Swirl tube
15. Master cylinder body
16. Reservoir seals
17. Reservoir
18. Low fluid level switch and
cap
NOTE: Thoroughly check that no debris is lodged in fluid passageways and drillings. If debris is
found, carefully remove, re-clean cylinder and re-check.
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