Re: [T3] Which master cylinder?

[Greg Merritt <gregm@vwtype3.org>]

<x-flowed>At 10:43 PM +0100 4/20/03, Mark Seaton wrote:
> Sorry- don't know the answer but would like to! But on that subject I
> noticed a bit of wettness around the rubber actuator rod seal on mine but it
> works fine and the fluid level doesn't go down. Likewise, when I looked at

Mark,

	Be afraid, be very afraid...

	The master cylinder in my '69 Beetle had been leaking here, 
likely for longer than I know.  That brake fluid ate floorboard 
paint, door sill paint, the tar board, portions of two carpet pieces, 
and the rubber floor mat.  The tar board was soaked and would ooze 
brake fluid like a sponge when poked.  Rust had begun on the floor 
board.  I had to pull out carpeting, remove the pedal cluster, remove 
the front seat, rip out the tar board, strip away paint, vacuum 
everything, clean everything, rust treat the metal, paint with 
POR-15, install carpet, and put everything back in.  (At that point I 
could install the new m/c and start the main repair.)

	Did my best to wash the rubber floor mat of brake fluid with 
soap, hose, and a push broom for scrubbing.  Even had to get under 
the car to slacken the clutch cable and get into the engine 
compartment to slacken the accelerator cable as I worked with the 
pedal cluster.  A bit of POR-15 in the brake stop mount hole and the 
pedal cluster mount holes made those bolt installs tougher than usual.

	I got to pay for some carpet, 3M carpet glue, por-15 kit, 
replacement tar board (have to buy the full set), and I don't know 
what else.  Oh, the car had the original (or at least original style) 
'68-'69 m/c, so I'm replacing with the '70+ model... which means I 
get to deal with the different wiring to accommodate the later 
switches and warning light arrangement.  (Oh, got to buy two 
three-prong switches to replace my good two three-prong switches. 
Sigh.)  So, yeah, I've spent more on parts and supplies than on the 
German m/c itself.

	So, I've spent hours and hours on this, taking care of all of 
the "extra" things that had nothing to do directly with the m/c 
removal and reinstall, all due to fluid leaking into the cabin at the 
pushrod boot.

	Do yourself a favor and repair/replace the m/c now, and hope 
it isn't as far advanced as it was in my car!

	(Insult to injury -- threads were damaged on the rear brake 
line fitting at the master cylinder, so I had to file the threads on 
that.  Big wing nut on the clutch cable was stuck kinda bad, so spent 
way too long on that.  Also, the rubber m/c filler rubber hoses were 
shot, so when I put fluid into the reservoir, it leaked out down 
below.  Also looks like there was some leaking at the upper res. 
hoses there in the Beetle's trunk, so I'm gonna strip/por-15 a patch 
in there, too.  Someday I'll drive the car again...!)

	Afraid yet, Mark?  I hope you can nip this in the bud and 
fare better than I did.

-Greg

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