Master Cylinder
#12
99-04 D2 Master Cylinder The brand is irrelevant as 90% of the aftermarket parts come from the same manufacturer, then it gets distributed out to multiple companies where it’s just slapped into a different box with a different name & price. LR water pumps these days are a prime example. Gates, Airtex, AC Delco, GRB = same part different box & different price.
#14
Two 13mm bolts hold it onto the brake booster, disconnect the brake lines, remove old MC, take new MC & bleed it on a bench, or install it onto the D2 fill with Dot 4 brake fluid then bleed it at the lines that enter the WABCO Unit. Then power bleed the brakes with a 15-20ft lead of wires & a toggle switch in place of the ABS relay. Power bleed it 2-3 times, then drive it and you should be good to go.
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MrHSE7 (09-28-2019)
#15
Atlantic British has a good youtube video of master cylinder replacement. Managing brake fluid spill is important since it will eat the paint and being sure you get the brake pedal linkage placed correctly are key. Apparently you can get it all put back together without positioning it correctly. Search the AB site for the link.
#16
Mine was leaking. It was worse in the cold weather. I found it frustrating that the seals couldn't be sourced separately so I just wrapped a small bungie cord around the reservoir and master cylinder. It held the reservoir down on the seals better with less wobbling. No more leak and it's been a year.
#17
Mine was leaking. It was worse in the cold weather. I found it frustrating that the seals couldn't be sourced separately so I just wrapped a small bungie cord around the reservoir and master cylinder. It held the reservoir down on the seals better with less wobbling. No more leak and it's been a year.
I had a friend buy an 04 and his reservoir leaked bad. I told him about the rebuild kit, but he said he just keeps it topped off. Well about 2-3 months later he was headed out to see some friends in FL. He made it to about Mobile, AL when his pedal went soft & he barely had any brakes. Lucky for him he didn’t have an emergency stop to make, but he did almost fly thru a 4 way intersection when he exited the freeway. He had to find a hotel & have it repaired before continuing onto see his friends. He was extremely lucky & I guarantee you he’ll never buy another D2 & just top off the leaking master cylinder again!
Not making fun of your fix, but be safe! 60.00 for a new master cylinder is nothing vs what could happen.
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