The brake master-cylinder is the component that controls the hydraulics for the entire braking system, front and rear. When you apply pressure to your brake pedal, it is the master cylinder that directs brake fluid to front and rear brake systems, allowing the car to come to a stop.
On the Alfa, the master cylinder is slightly unusual in its mounting orientation. Specifically, the master cylinder on the Alfa is mounted pointed toward the rear of the vehicle, while on most vehicles it is mounted facing forward.
On the Alfa, feeder lines bring brake fluid down to the master cylinder (figure A), and servo lines carry it out. The mounting orientation on a conventional master cylinder (figure B) allows brake fluid to enter via a fluid reservoir above the cylinder (figure C), and exit the cylinder via actuator lines on the side of the cylinder. The reverse orientation on the Alfa is designed to work in conjunction with two servos in the engine compartment. In this case, applying pressure to the brake pedal engages a servo booster which, in turn, engages the hydraulics to the brake calipers.
In our restoration, new servos and master cylinders were no longer available for the 1969 Alfa, so the parts need to be removed and refurbished.
Following are the basic steps for removing the master cylinder and servos.
- Remove the cotter pin that holds the braking fulcrum where it's connected to the master cylinder (figure D). Take care not to lose the small cotter pin, as it will be needed later during reinstallation.
- Disconnect all of the brake lines from the master cylinder (figure E). The rusty color of the old brake fluid shows how brake fluid can absorb moisture and cause rust from the inside out.
- With the brake lines all disconnected, loosen the retaining nut that holds the master cylinder in place (figure F) using a socket wrench.
- With the nuts removed, carefully remove the master cylinder (figure G) and set it aside.
- With the master cylinder removed, move on to removal of the servos that are mounted to the firewall inside the engine compartment. Use liberal amounts of penetrating oil to help loosen the metal connections and hoses on the servos (figure H).
- Use hose cutters to cut the old servo hoses (figure I) for easier removal.
- With the hoses out of the way, begin work disconnecting the steel lines from the servos (figure J), being careful no to cause further damage to any corroded connections.
- With the lines all disconnected, loosen and remove the servo mounting nuts, and carefully lift out the servo (figure K).
- Repeat these steps for the second servo.
The servos and master cylinder are critical to the brake system, and are no longer available as new parts, so it's important to avoid damaging them during the removal. Once removed, they can be sent out to be refurbished.
RESOURCES :
Alfa Romeo Owner's Bible: A Hands-On Guide to Getting the Most from Your Alfa
Model: 0837607078
Author: Pat Braden
Order this book from Amazon.com
Bentley Publishers
Alfa Romeo Spider: The Complete Story
Model: 1861261225
Author: John Tipler
Order this book from Amazon.com
Crowood Press
Original Alfa Romeo Spider (Bay View Original Series)
Model: 0760311625
Author: Chris Rees, James Mann
Order this book from Amazon.com
Motorbooks International (MBI Publishing)
Essential Alfa Romeo Guilia & Giulietta Coupes & Spiders: The Cars and Their Story 1954-95
Model: 1870979591
Author: David Hodges
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Motorbooks International (MBI Publishing)
Alfa Romeo: The Spirit of Milan
Model: 0750919582
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Sutton Publishing
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
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Author: Jim Richardson
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H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
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Haynes Publishing
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