The first winter I owned my D2 I noticed the RED brake light came on and I was down a bit of fluid. I topped it off and watched the system and nothing happened, although I had to wipe some brake fluid off of the top of the Master Cylinder.

Next summer I was fine, and sure enough, when the temperature dropped, it got low again.

The culprit (and many on this forum have helped me track it down) were the pesky grommets that separate the overfill reservoir from the Brake Master Cylinder.

I ordered a kit and last spring I filmed the repair. I finally got around to editing the footage and uploading it to YouTube.

The job is pretty straight forward and requires nothing more than some PPE (so brake fluid doesn't get in your eyes and all of your hands), a pump, some screw drivers, and needle-nosed pliers.

I'm posting the link here for historical purposes, so if anyone else is troubleshooting an intermittent brake fluid leak, a forum search will lead them to this video.

If you have done the job before and have any other tips/tricks that are different from the video, let's hear 'em. This was my first time doing the job, and I may have done it the "hard way".

 

 

 

I hear Hollywood calling. Thanks for link to your video.

May have been lucky or by catching leak before air got into the system bleed wasn't necessary after my replacement.
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I can't remember where I got the reservoir kit, it was either Rover's North or Atlantic British, whichever was cheaper at the time. It came with a new filter, new reservoir, new grommets and another part that connects into the master cylinder, but we didn't replace that part, since my only failure was the grommets.

It kind of stinks spending that kind of money for essentially $5 seals, but you saw how discolored the old one was due to 10 years of being cooked by the engine heat, it was probably a good idea to change it.

I did bleed the brakes, but just using the standard method of bleeding them at the calipers. The fluid needed to be swapped out, it was gross.

I don't have the computer to do the ABS bleed, or I would have filmed that too.

 

Grommet kit for the reservoir.





https://www.powerbrakes.com.au/shop/...7003/offset/0?

 

Thanks Abran!

That is what I will do next time. My original reservoir was so cooked by the engine heat, it needed to be replaced anyway. You couldn't even see where the level was anymore. But if it leaks again, just getting the grommets are the way to go!

 

Saw those a couple of years ago when looking. What's the cost after shipping is added? If you've used these before why not order a quantity and add to your list of items you offer?
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In all honesty if the reservoir grommets are cooked/perished the internal seals will soon be a problem also. IMHO you have a couple of choices, a completely new master cylinder or a repair kit RTC583

https://www.lrdirect.com/RTC5834-Rep...yl-Girling-Da/

 

I have a few sets on hand, if someone needs one I could let go of it. As a business I dont see it worth the hassle.

An organized group buy by a member makes more sense.

At today’s exchange rate a set is $17 USD, then there is the crazy shipping from OZ.

So let’s say the cost is $25 a set, I dont see it feasible to sell these for $35 or more. Stocking, shipping, dealing with returns, etc. isn’t justified based on the price.