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Posted by: jsaum Dec 28 2009, 01:14 AM

Anyone have advice on the best way to get the reservoir tubes and grommets into to the master cylinder? I couldn't get them to slip in with the grommets in the master cylinder so I tried pushing them on the metal tubes and then pressing them in neither way is working. I have every thing else in place.

Posted by: ArtechnikA Dec 28 2009, 05:09 AM

search before starting work...

This is your problem.

Detach the tubes from the reservoir and pull them down and out of the car.
remove the MC from the car and insert the tubes and grommets ON THE BENCH where you can get leverage from above.

Then thread the tubes back up through their holes, remount the MC, reattach the hard lines, ta da.

Posted by: GeorgeRud Dec 28 2009, 06:50 AM

Rich's way is by far the best way, but if you really want, I had success by heating a closed end wrench, bending it 90 degrees, cutting it to make a kind of crowsfoot wrench, and putting a screwdriver through the other side to make a handle. Fitting the bent end over, cut end over the grommet and tube, it should hang down below the master cylinder. You then simply hang off the handle, curse the fellow that designed this, and pray that the grommets pop into place!

Honestly, the bench assembly is much easier on your nerves!

Posted by: DBCooper Dec 28 2009, 07:31 AM

There are aftermarket M/C's that I swear won't fit no matter what. If you're trying to install in one of those try re-using the ATE grommets (they don't seem to wear out) taken out of the M/C being replaced, put them in the new M/C, THEN try these tricks.

Posted by: jsaum Dec 28 2009, 10:39 AM

Thanks for the tips I'll pull the lines and start over practice is always good!

Posted by: SLITS Dec 28 2009, 12:04 PM

The aftermarket one is the Euro Parts one. They do not put the washers under the grommets and the grommets are slightly different. I reused the ATE washers and grommets and they popped right in.

Posted by: SUNAB914 Dec 29 2009, 08:55 AM

I used two lockjaw pliers to pull down on the line. Probably some silicon spray on it too. It's a pain. I might try the pulling the lines from the resevoir next time.

Posted by: Cap'n Krusty Dec 29 2009, 09:50 AM

"Pull the lines from the reservoir"? THAT sounds like the hardest way of all. Install the grommets and the washers, lube them with brake fluid, install the m/c, and pull the tubes in with a pair of needle nose vise grips and a sturdy hook tool. Sure it's hard, but so is life. Suck it up, folks. The Cap'n

Posted by: jsaum Dec 29 2009, 01:06 PM

I bit the bullet and took the harder route pulling the gas tank! The master cylinder is in brake system is completly rebuilt and on to the next project the fuel system! Oh what fun!

Posted by: RiqueMar Dec 30 2009, 12:41 AM

I'll be noting this topic in a few days. I was just cleaning off my resevoir and have a new bigger MC.

Posted by: rfuerst911sc Dec 30 2009, 04:32 AM

Here's how I did it. Loosen the clamp that hold the reservoir to the bracket. You can now push both brake lines down with the reservoir attached. With the steering rack cover removed push the lines down about a foot or so. Now the lines are out in the open where you have leverage. With the master cylinder in your hand pop each line in, very easy because you have leverage. Then slide the lines up until the master cylinder is in place. Install master cylinder and then put reservoir in place and tighten clamp. This whole process took me about 10 minutes. More than one way to skin a cat .

Posted by: etcmss Dec 30 2009, 06:16 AM

I did it your first way and struggled and was successful. it wasn't fun and didn't know better at the time that there was another way.
but now you have the gas tank out for the fuel system project.

Posted by: greenie Dec 30 2009, 07:54 PM

It's about time...how long have you been working on (talking) about getting this thing on the road?

Good progress ! I'll have the "Orange One" driving before your car see's the pavement.

Posted by: ppeters914 Dec 31 2009, 11:21 AM

This thread started about reinstalling the reservoir lines, but what about removing them?

I pulled the pedal cluster to rebuild, and discovered the brake master cylinder weeping. Disconnected the 3 brake lines, but damned if I could figure out how to disconnect those two lines on top of the master cylinder. The responses on this thread aren't clear to me.

I get that you need to get slack in the reservoir lines, but you pull them all the way out? How the heck do you feed them back unless you have the gas tank out?

Pete
71 1.7L

Posted by: ppeters914 Dec 31 2009, 11:33 AM

Ack! Never mind. Found Pelican Parts tech article on upgrading the master cylinder. Apparently, the reservoir tubes are just an extremely tight press fit into grommets.

Posted by: jsaum Dec 31 2009, 12:51 PM

Cool then you can lend me the green one to drive!

Posted by: ArtechnikA Dec 31 2009, 01:00 PM

I don't remember - it was a mere 30 years ago...
But I don't recall it being difficult. I'm thinking i took the grommets (not the MC grommets, the line/body-seal grommets) out from the top and then with the stiff lines it was a pretty straight shot up from the bottom.

The lines are not quite 'just' a press-fit into the grommet. There is a flare at the base of the metal tube. So you pretty much have to pop the grommets out first and press them in last.

John's method is much easier if the car is on a proper lift and you have room to use your arms and body weight to assist. If the car is on jackstands and you're lucky to be able to just get your arms bent, it's _really_ hard to manage with just the strength in your fingers. Especially if you don't do this kind of thing every day.