A was for Austin, but now B is for Bedford

Couldn't sit around doing nothing so took the master cylinder and servo back off. Stripped the check valves out, reassembled it with some of the spare brass cups - but without the rubber cups in them. Brake fluid everywhere.

By the time I had finished putting it all back in the truck the light was fading, and so was I. At least this will remove any restriction for the brake fluid to return to the cylinder, and that particular possibility will be eliminated??? - If that doesn't work it will be into the back end, groan. 

Tomorrow morning the Men's Shed will be cleaning and revarnishing the town's tables and seats (full and busy morning although with twelve of us on the job we should get most of them done). Pause for lunch and then off to Bingo in the afternoon, time to relax a little at least.

Roll on to Wednesday, another bottle of brake fluid and try again.

PS   I don't really hate the truck, just this bloody persistent issue!  

Sounds like the mens shed is a welcome distraction at times

Paul

PDU, brakes are overrated. 

I agree with V8

Why don't you put a couple of zip ties around the handbrake ratchet trigger and hook the handle up with a couple of pulleys and cable to the brake pedal.

Yes it is Paul, and thanks for the laugh before heading out this morning V8Ian and Lang, it's what I need right now . . . 

Another bottle of brake fluid through the system and some signs of life, despite some shitty stuff coming through the bleed nipple and into a jar. Nothing a good flush through with new brake fluid won't fix(?). Except for today I've run out of new brake fluid again!

Having gone as far as I could by myself I called in the guy who spotted the master cylinder bypassing the piston, and with him pumping the pedal (still with some air in there!?) brakes were working AND releasing. Not how I want them yet, but decidedly better, and actually showing signs of doing what it's supposed to do.   

That's progress, I would count it as win

Well done, your heading in the right direction now by the sounds of it

Paul

Question?

Did you prime the master cylinder with fingers over the holes and a gentle press a few times to fill all the chambers. 
 

An impossible dream jon_d, it is a nightmare getting anywhere near the hole along the chassis side. The brake line comes straight out towards the chassis rail and then does a right angle turn to go to the back axle. The tube nut gets pushed back onto the radius while attempting to pick up the thread and then jams  - it can't even be tapped back free because the back of the nut is tapered and the blow just slips past. The only way to free it is to turn it and work it forward again, which sounds easy except you can't even manage one flat without flipping the spanner over halfway through. If that doesn't make sense don't bother, basically sheer dogged determination gets it done! So, bottom line, no I didn't, because you lose brake fluid as the cylinder has to be tipped on an angle sideways to get it into position. Basically it’s a case of pumping brake fluid through the system until any air is pushed out.  

Added to the problem is access to the brake cylinder, which is under the seat. This probably wouldn't have been a problem if I had used the original Bedford seat which requires a simple removal of the squab for access. My seat is firmly bolted down, with tight but reasonable access for checking and topping up brake fluid, but not for sustained filling and pumping as I will need to do. 

Tomorrow afternoon (after Heritage Centre) I will be looking at making a remote filler with a tube running through the master cylinder cap, similar to a lot of older English vehicles like the Austin A40 illustration below. Some even had an electrical connection to a bulb warning you that your brake fluid reservoir was in need of topping up.   


Whatever, after what I have been through so far I consider myself on a winning path Mrsmackpaul and I think I can now see the train coming through the tunnel!?   

The next session will be Friday morning with my new helper Geoff (ex RAA mechanic) and after my wife picks up some more brake fluid for me while she's in Port Pirie tomorrow morning. Despite the access issues I am feeling confident that things will work after this (or is that tempting providence?). 

PDU,
I have given up on buying the little (600mil?) bottles and now buy the bigger ones. I do keep the little ones, topped up from the big ones, in the car and truck toolboxes.

The remote filler tank for the master cylinder is a good idea. When I get around to it, I plan to fit one to my Morris three tonner as the master cylinder is below the driver's feet and under the insulation and the screwed down floor mat. You would have to blank off any breather hole in the cap.

Please reread my earlier post about replacing all rubber components in the brake system, including hoses and flushing lines after rebuilding or checking cylinders.

Morris.