Traction Owner’s Club › Forums › Technical › Brakes › Master cylinder refurbishment issues.2819
I have a new seal kit from Chris to refurbish my brake master cylinder on my 1957 Big Boot. I have previously replaced all seals and rubbers on the wheel cylinders and this was my final job. Once I had figured out how to get the master cylinder off it was stripped out and the old rubbers discarded. The cylinder bore was in perfect condition with no scoring or signs of rust and so the new seals were used and the cylinder replaced in the car and connected to the reservoir. The front driver’s side brake was bled and the pedal was firm. on checking the fluid level, despite topping up, was lower than I anticipated and gradually dropped until the reservoir was empty. On inspection it appeared the fluid was leaking from the back of the master cylinder. I dismantled everything again and cleaned each part meticulously in case anything was trapped under the sealing rubber on the piston. I jury rigged a supply to the cylinder while on the bench and the leaking continued. After several disassemblies and reassemblies the leak appeared to stop and I remounted the cylinder in the car and bled the brake as before. To my utter dismay the fluid started to drop into the cavity in the body and out onto the floor. Has anyone had such an experience or have a solution or suggest a possible cause. Chris has suggested I bite the bullet and buy a new cylinder but I would like to resolve this problem if possible.
John Moon wrote an article on the master cylinder in FP recently (Vol 46, issue 3, page 16).

For fluid to leak out it must be getting past the seal which is identified as item 7. John says this about that seal:
“Seal (7). This fits in a recess in the piston but although there are 2 different seals supplied for this, in my limited experience, neither of these fitted the pistons I looked at. Obviously there are many standards of piston out there from different manufacturers over many years. My only suggestion is to contact “Past Parts”, recommended by Mike Wilcock recently.”
Dear Chris,
I read this article and examined the diagram which is essentially the same as my master cylinder. The seals in the kit were correct for my cylinder so no reason to suspect otherwise. However, I think I may have solved the problem but why my modification should make any difference I am not sure as the previous set up was OK (yes, I know, if its not broke why mend it). I realised that the rear seal on the piston was almost against the thick stop washer that’s held in with ring clip. The machining or casting inlet to the bore of the cylinder where the recess has been made for the spring clip is just slightly larger than the true bore so the seal had partially lost its ability to seal hence the leak. In order to attempt to rectify this I placed a thick rubber washer between the piston and stop to prevent the piston being pushed all the way back by the spring. So far the leak has not again manifested itself but I still need the replacement hoses as one of those certainly does leak.
Thank you for your support, best wishes, Joseph
