DIY Network

1938 Packard: Checking Brake System, Brake Hoses and Removing Master Cylinder From "Classic Car Restoration" episode DCR-405

When Packard introduced technology like their air conditioning or hypoid gears, these features usually became the standard of the industry.

In this episode of Classic Car Restoration, host Mark Lambert evaluates the brake system on our 1938 Packard, checking the hoses and master cylinder. He removes and rebuilds the master cylinder and then re-installs it. He also shows how to make new brake lines using a metal tubing bender. Lastly, he bleeds the brakes and makes the final adjustments. In this first segment of episode 405, Lambert sees what work needs to be done to the brakes and removes the master cylinder.

Brief History

In the 1930’s, hydraulic brake technology was still evolving. Much of the industry was using old-fashioned cable brakes when Packard brought out its hydraulic brakes on the first model of our car, the ’35 Packard 120. Therefore, in the brakes of our ’38 Packard you get tremendous longevity of design. This same basic brake system was used all the way to the muscle car era.

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Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

System Evaluation

When Lambert test drove our car, it stopped nice and straight but the pedal was mushy. He discovered that there was a torn master cylinder boot (figure A). The brakes, on the other hand, looked really good. They were solid, but if you have a brake line that looks like this (figure B) it is critically important that you replace it because this is a single action unit. If you lose one brake line, your entire system goes down.

Figure A

Figure B

Figure C

The brake hoses looked fresh. We did have a bad break hose, though. If you can see small cracks, the hose has been shot for a while. A new hose is a stark contrast to an old one (figure C).

Materials used in this episode:

Standard automotive tools (socket-wrenches, screwdrivers, nut-drivers, etc.)
Regular drill with break honing bit
Replacement break fluid
Replacement master cylinder kit
Tapered drift punch
Tubing cutter
Tubing flaring tool
Tubing bender
Brake spoon

Removing Master Cylinder

• The master cylinder is located in the engine bay, behind the brake pedal. It stores the brake fluid.
  

  	Figure D
  	Figure E

• Remove tire and brake drum . Peel back and check the wheel cylinder (figure D). Ours was nice and dry, which is a good sign. If you have a lot of fluid there, you have a problem and need to replace.

• Begin by removing the electrical leads and then take the hydraulics off. You will have to catch the hydraulic fluid when you break the ¾ nut free (figure E).

• Loosen the master cylinder and begin pulling the rest of the hydraulics off. Be careful not to lose the washers.

• Once the master cylinder is free, push the hydraulic lines down gently and pull the cylinder out. Your pedal will fall because all the tension is lost.
  
  
  

  RESOURCES :
  
  
  Resources and Special Thanks for Classic Car Restoration 400 series
  
  
  The Packard Club
  Columbus, Ohio
  (National & regional clubs, car shows & judging, magazine, resources, etc.)
  The Cormorant magazine
  The Packard Club
  www.packardclub.org
  
  Packards International Motor Car Club
  (National owner's club, judging rules, magazine, newsletter and other resources)
  Santa Ana, CA
  Packardsinternational.com
  
  Packards of Chicagoland
  (Regional affiliate of The Packard Club)
  Elmhurst, IL
  Packards of Chicagoland
  
  America's Packard Museum
  Dayton, Ohio
  www.americaspackardmuseum.org
  
  The National Packard Museum
  Warren, OH (the birthplace of the Packard)
  www.warren.org
  
  The Packard Motor Car Foundation
  (Foundation for preserving the Packard marque) Restoring the Packard Proving Grounds and other Packard activities.
  www.packardmotorfdn.org
  
  Motorbooks International
  www.motorbooks.com
  
  Automobile Inspections LLC
  (Nationwide automobile appraisal & inspection services, including classic cars)
  Hartford, CT
  www.automobileinspections.com
  
  Classic Auto Appraisals (Evaluation of Classics, Street Rods, Antiques, Competition Cars, Exotics, Commercial Vehicles and Hand Crafted Vehicles).
  www.autoappraisals.com

  ALSO IN THIS EPISODE:
  	1938 Packard: Checking Brake System, Brake Hoses and Removing Master Cylinder
  	1938 Packard: Rebuilding Master Brake Cylinder
  	1938 Packard: Master Cylinder Installation, Metal Brake Tubing Demo
  	1938 Packard: Bleeding Brakes, Final Brake Adjustment