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PostPosted: Sat Jun 29, 2013 12:32 pm 
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Joined: Fri Jun 28, 2013 11:13 am
Posts: 26
My Location: Southport, UK
My Car: Rover 75 CDTi
A lot of the information in this guide is derived from the excellent work by the guys on roverki.pl - thank you!

A massive thank you to the member on MG-Rover.org who supplied me with a Rover 75 Clutch Master Cylinder on which to perform this rebuild, and hopefully help to cure the 75/ZT Master weakness once and for all.

This isn't the final 'fix' for the weak Master cylinders, however can certainly help you get a much longer life from your existing Master cylinder. When performing this modification, make sure you bleed and flush all old brake fluid etc from the system.

This guide shows you how to fit a Honda Civic / Accord Clutch Master Seal to a Rover 75 Master, resolving the problem of leaking seals or one way valves.

The Master cylinders usually either start to leak due to seal failure, or the small 1 way valve within the piston assembly itself starts to leak causing loss of pedal pressure.
This solution replaces the main Master seal and the 1 way valve, which in the majority of cases will allow your Master to work for many years without issue.

Here we have the Rover 75 Master I have for stripping down:
Image

First, remove the rubber boot and the plastic clip holding the piston within the Master:
Image

Next, remove the piston assembly:
Image

This is the main Master seal, and the white cap is the container for the 1 way valve and spring:
Image

Upon removal, you can see the tiny piston for the 1 way valve:
Image

Finally, pull and twist the main seal assembly from the end of the piston:
Image

Inspect the bore of your Master Cylinder carefully. It MUST be free from scratches. If you have any very minor scuffs, you can correct them with very fine (2400 grit) wet and dry dipped in brake fluid.

If you have more than a few minor scuffs, a metal Master Cylinder body is available from Poland. You'll need to use your piston assembly however - it's supplied as the housing only.

Luckily the bore in this Master was perfect, so onwards and upwards.

The old system is show below - picture courtesy of roverki.pl:
Image

The new system, with the Honda Civic / Accord (etc) clutch seal - picture courtesy of roverki.pl:
Image

To fit the new seal, you will need the following:
- Honda Civic / Accord clutch master seal - Autofren D1357 / D1381 The seal needs to be standard 5/8" (15.8mm). 2 seals are used within the Honda / Toyota master, you're looking for the smaller one (7mm inner diameter).
- M8 bolt, with allen hex head to avoid scuffing the cylinder. The bolt needs an unthreaded shank of at least 6mm, as the replacement seal will use this as a sealing surface. The bolt needs to be between 20 and 28mm long.
- M8 washer, make sure it is less than 15.5mm wide so it clears the bore of the Master with room to spare. It needs to be at least 15mm wide to provide a good base for the seal. 1mm thickness is ideal.
- Adhesive, generic superglue will do however epoxy such as JB Weld is recommended. Loctite 480 is also good for this application.

You need to drill the hole in the piston to 7.5mm, and to the depth of your chosen bolt minus the depth of the new seal and washer.

You can apply some glue to the threads of the bolt to stop it coming out again, however this isn't necessary. You will however need to bond the washer to the piston, as this needs to be a brake fluid tight seal. Do not glue the seal, as this will affect the rubber.

The finished item should look this this - image courtesy of roverki.pl:
Image

Once done, fit it all back together and bleed as needed. Remember to fit the plastic clip holding the Master assembly together.

Good luck!

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Rover 75 Connoisseur SE CDT - 2001
Owner and founder


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PostPosted: Thu Jul 04, 2013 12:15 am 
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Joined: Sat Jun 29, 2013 3:12 am
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Will you be selling a kit for this Matt ?
What is the purpose of the valve ?


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PostPosted: Thu Jul 04, 2013 11:59 am 
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Joined: Fri Jun 28, 2013 11:13 am
Posts: 26
My Location: Southport, UK
My Car: Rover 75 CDTi
carl wrote:
Will you be selling a kit for this Matt ?
What is the purpose of the valve ?


I'm going to try, I'm also in the process of sourcing a metal Master Cylinder body to fit this new piston into.

The valve seems to be purely to equalise the pressure, but as you can see there's a channel from both halves to the reservoir.

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Rover 75 Connoisseur SE CDT - 2001
Owner and founder


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PostPosted: Fri Aug 30, 2013 7:56 am 
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