Defender. Manual - part 42
caused to new seals when inserting plungers into cylinder bore. Generous amounts of new brake fluid should be used to
lubricate parts during assembly.
• NOTE: Thoroughly check that no debris is lodged in fluid passageways and drillings. If debris is found, carefully
remove, re-clean cylinder and re-check.
1. Install new swirl tube to bottom of cylinder bore.
2. Lubricate secondary plunger and cylinder bore. Offer
plunger assembly to cylinder until recuperation seal is
resting centrally in mouth of bore. Gently introduce plunger
with a circular rocking motion, as illustrated. Ensuring that
seal does not become trapped, ease seal into bore and
slowly push plunger down bore in one continuous
movement.
3. Install primary plunger assembly using same method as for
secondary plunger, push plunger down bore.
4. Install original guide ring to support primary plunger.
5. Coat a new O-ring with brake fluid and install to its
respective groove on outer location surface of master
cylinder.
CAUTION: O-ring should not be rolled down outer location surface of master cylinder but should be slightly
stretched and eased down cylinder and into its groove. Do not over stretch seal.
6. Install a new retaining ring on outer surface of master
cylinder ensuring that serrations of ring are facing mounting
flange.
7. Install two new reservoir seals in their respective ports.
8. Install a new vacuum seal to either primary plunger or to
bottom of transfer housing bore, open face of seal towards
primary plunger guide ring.
9. Lubricate vacuum seal with brake fluid, install transfer
housing to master cylinder, push housing fully up to cylinder
mounting flange. Do not adjust transfer housing after fitting.
10. Lubricate a new water ingress seal with brake fluid, slightly
stretch seal and ease it down housing until seal is in correct
position between housing and flange.
11. Roll reservoir into top of master cylinder, reversing
procedure described in instruction 3.
12. Install master cylinder to booster.
For additional information, refer to:
Brake Master Cylinder
(206-06 Hydraulic Brake Actuation, Removal and Installation).
13. Reconnect battery, and road test vehicle.