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Master Cylinder Rebuild - Plunger rubber installation

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  • Master Cylinder Rebuild - Plunger rubber installation

    Master Cylinder Rebuild
    Plunger rubber installation

    by Ken Talbot, 2/26/02


    I'm really stumped. Any ideas on how the rubber seal is placed onto the plunger inside the master? It is a small rubber cap and the plunger has a large diameter disk at either end and the seal goes in the middle. The old one is in the center of the plunger and the rebuild kit has the parts separated. At $60 bucks
    Canadian I'd hate to mess it up.

    Dave Jardine


    The rubber seal is quite flexible, Dave, and will take quite a bit of
    twisting without tearing apart.


    Start with the plunger and seal laid out like this, to be sure of which way the seal is going to face


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    Roll the seal inside out and slide it up the shaft of the plunger so is comes up against the collar


    Click image for larger version

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    Slide a flat screwdriver blade under the seal and up onto the collar


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    Lever the screwdriver over to start bringing the seal into position. Get it far enough over so it won't slip back. Notice how the seal is turning back to right side out as this happens


    Click image for larger version

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    Use your fingers and thumb to roll the seal the rest of the way over the collar


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    Check that the seal is sitting in its groove where it belongs.

    Voila - you're done!


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    Last edited by tplank; 11-14-2020, 01:25 PM.
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