Vehicles

sonett - removing clutch master cylinder, brake master cylinder, and fabricating new pedal mount

When I got the car I could not press in the clutch or brakes. I immediately thought the master cylinders were siezed. As it turns out, the pedals themselves had rusted in place. Once I got the pedals removed, I could see that the clutch master cylinder was also siezed. The brake master cylinder appeared to be working fine.

I would have to remove the clutch master cylinder to have it rebuilt (or possibly just replace it). This was easier to do if I also removed the brake master cylinder since it sits in the way of access to the clutch mc.

Each of these units are secured in the same manner, an upper nut and bolt and a lower bolt welded to the inner firewall and a nut accessible from the engine bay. Access to these units is tricky. The brake master cylinder is somewhat accessible, but the clutch master cylinder will have to be removed by touch. Not too bad since there are only two bolts holding it on.

Removing the nut from the welded bolt is no problem. Removing the bolt from the free spinning upper bolt is annoying. You have to get someone inside the car to hold the nut in place while you undo the bolt from the engine bay, or vice versa.

Before I could remove the brake master cylinder I had to undo the hard brake lines. not too difficult except for the brake lighting switch. It attaches to the front banjo bolt. You have to disconnect the two tiny wire leads from it before loosening it otherwise the wires will get wound up and probably break.

I also removed the fluid reservoirs and fluid lines. Mine were both empty so that made that part easy I guess.

Now I just need to find someone to rebuild these units.

While they are out, this part of the car could use some cleaning up. I plan to do some wire brush and paint work. Nothing to major, just enough to keep it from getting worse. Once the car is fully functional, I plan to come back and do a proper frame and metal work restoration.

Pictures

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salt deposits from cleaning out the inside of the car
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salt is visible at the drain hole
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ugh, this area looks pretty terrible
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debris cleaned up
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wire brush used to clean up metal, actually no holes, metal looks good
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its like a salt shaker in here
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ended up doing more cleanup in the area to address some of the bubling paint
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saab used some sort of caulk between the metal pieces. This stuff is still flexible even after 40 yr
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brake pedal cleaned up
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braket made out of steel, will allow me to reattach the support I had to cut off earlier
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the bracket will be bolted to remaining existing bracket and also the floor
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fluid reservoir bottles
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brake master cylinder barely visible
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brake master cylinder bottle removed
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the brake fluid line was perished to say the least, it splt in two with no effort
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annoyingly, the bolts holding the bottle brackets in place attach to loose nuts on the other side
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brake master cylinder, notice two banjo bolts, front one has brake light switch on it to the right
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better shot of brake light switch
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top bolt removed from engine compartment, lower bolt welded in place
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looking pretty rough
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lockheed 3211-823C C8, at least that looks like the part number, not sure
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removing brake master cylinder provides much better access to clutch master cylinder
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two identical red wires are for brake light switch
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clutch master cylinder in forground, slave cylinder in background
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Girling 09 BS maybe, not sure, clutch slave cylinder
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girling 5/8, clutch master cylinder
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inside of clutch master is looking pretty foul

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