Master cylinder repair/replace

[Tom Chace]

I did an inspection of my brakes today and found a broken fitting which should be attached to the rear section of the master cylinder.
The connection has a wire fed into the connection and the connection had a small spring and possibly plunger. Looks close to impossible to work on without removal.
The rear part of the cylinder looked to be wet with fluid - checked the levels and added 1/4 small bottle to bring the level to 1/8 " from top as recommended.
The brakes work but have always been hard to push - I think this may be the cause??

Does anyone have experience with this problem and recommendations for repair?
Does anyone have a Magnum Chassis Repair manual - RE brake repair ?

Thank You

Tom

[Karl Welhart]

Tom,

What model and year coach do you have?

Karl

[Jerry Emert]

I would also be interested in a Magnum Chassis repair manual.  Thanks
Jerry

[Karl Welhart]

Tom and Jerry,

Not sure if there are any real repair manuals for Magnum chassis'.  There are so many configurations and some have very different designs.  For example, the Magnum chassis used in Safari are nothing like the ones used in the Beaver line.  The Monterey used a very different design then the Patriot or Patriot Thunder/Marquis.

The good news is that most of the components are standard medium/heavy duty truck stuff and readily available at most truck parts and mechanics that know the medium/heavy duty truck business understand the mechanical nature of our MHs.

This all sounds great until we DIY's try to repair stuff.  THAT IS WHY THIS FORUM IS SO GREAT!

Karl

[Tom Chace]

Karl

Our coach is a 36' 2000 model Beaver Monterey 300 CAT all disc pac brakes

And YES this forum is a great source for all types of info
Thank You

T

[Karl Welhart]

Tom,

Your chassis is a very unique situation.  Just adding fluid (I assuming it was brake fluid) should not change the pressure necessary to apply the brakes.  Could this fitting be connected to the brake light switch?  If so, that switch should be readily available at any truck parts store.  Do your brake lights work?

I would recommend a brake fluid flush and refill.  That may help your brake peddle pressure issue.

Karl

[Gerald Farris]

Tom,
There are two types of switches that are used on your type of brake systems. One is just a pressure switch that turns on the stop lights when the brakes are applied, and the other one, the balance switch is used to turn on a brake warning light on the dash when the pressure is much higher at one axle than the other. I would have to see the switch, and it's location in the system to tell you which one it is, but neither switch will make the brakes harder to apply.

I have not worked on the brakes on your model coach, and the stop light may be a pedal travel switch instead of a pressure switch, but a switch is not causing excess pedal effort.

Gerald  

[Tom Chace]

As to the switch, The lights were not working - I fixed that - had a broken wire at the brake light actuator switch - all good now.

The wired connection that I saw seemed to be an indicator light type. It is on the rear part of the master cylinder on the chassis side - very difficult to see - I need to get my mirror out.
It is a white connection, one side mounted on the Master Cylinder the other is a clip with a wire ( this is the broken one)

As to pedal pressure, when I checked the oil level - the dot3 seemed sticky. almost glue like. I didn't like the feel and thought a clean out might make sense. It has probably never been done before as I have only had the coach for  a year.
My plan is to take it to a mechanic, have the M C checked and change out all brake fluid to fresh and ask about the pedal pressure.

Thanks to all and I appreciate any and all help

One other thought
Last trip back north on the east coast GA, SC,NC,MD & VA DOT were prepping for a snow storm with liquid salt??
I won't drive on the highways until the stuff dries a bit, It really eats electric connections

[Tom Chace]

As to pedal pressure, when I checked the oil level - the dot3 seemed sticky. almost glue like. I didn't like the feel and thought a clean out might make sense. It has probably never been done before as I have only had the coach for  a year.
My plan is to take it to a mechanic, have the M C checked and change out all brake fluid to fresh and ask about the pedal pressure.

Any Ideas???

[Karl Welhart]

Tom,

Make sure that your mechanic empties the brake fluid reservoir, then fills with fresh DOT 3 or 4 (I prefer 4) fluid.  Then he should start to flush the system starting with the PS rear brake caliper, then the DS rear, then the PS front, and finally DS front.  The brake fluid reservoir should be refilled after each corner has been flushed until the fluid color is clear....  You will notice a huge difference in the peddle feel.

Karl

[Tom Chace]

Thank You to all!

We really appreciate the help.

Safe travels.

Tom and Pam