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Repairing the Brake Systems

Repairing the Brake Systems

Posted by Justin on 5/6/2005
Neither brake was working very well, but the rear was almost nonexistent. The rear master cylinder cover is broken, the rear brake line has a tear in the outer rubber layer, and the master cylinder was empty except for some sludge. The guy who sold it to me mentioned that the front brakes might need a rebuild as well.

Images
Inside the rear caliper
I took the piston out and found that the cylinder was full of the same green sludge that the master cylinder had
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Cutting away the mounting nut seat
The original hex-shaped hole where the nut for the mounting bolt fit was completely stripped so I cut the whole chunk out with a dremel
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Inside Master Cylinder
Even after cleaning out the sludge with a rag its still pretty ugly inside.
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Rear Brake Caliper
The hex-shaped seats for the nuts on the mounting bolts, as well as the nuts themselves, were stripped. One of the bolts had to be cut using a dremel cutter.
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Rear caliper dents
A quick buffing got some shine on this caliper but the dents and deep scratches will require some heavier sanding and grinding
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Rear Master Cylinder
The plastic top was cracked in half and there was no fluid in the reservoir
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The other stripped caliper piece
This hole isnt quite as stripped as the other one but the nut spins freely so it'll have to be cut back as well
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Where the rear caliper bolts on
... apparently to this large ugly chunk of cast aluminum
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Where the rear master cylinder bolts on
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Carlsbad CA  US
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