5.1 Clutch
Parts required: - 042
1. Start off by removing the blank from the clutch master cylinder (042) and screw in one end of the
clutch flexi hose. On the other end screw on the Banjo union supplied with the clutch slave cylinder
(this will be connected up once the engine and gearbox assembly has been fitted). Pass the push rod
end of the master cylinder through the mounting hole just in from the torsion bar mount and secure
with the 5/16” UNF supplied. The clutch will be finished off once the engine and gearbox are fitted.
5.2 Brakes
Parts required: - 039 – 041
1. Start with the master cylinder and servo (040). Mount the master cylinder using the mount plate with
captive studs. Pass these through the mount position next to the clutch master pointing forwards
before offering up and securing the master cylinder with the two washers and nuts supplied. Next
mount the servo on its mounting plate. These holes are unequal so it will only mount one way round
(the servo needs to be mounted in a particular orientation to work correctly) before mounting the
bracket on the chassis with the three 5/16 UNF x 1 bolts washers and Nylocs.
2. The two fluid reservoirs mount with clamp plates to the two lugs welded to the chassis tube above
the brake servo. These can be test fitted with the connection pipes but will need removing before the
body can be fitted.
Front brake lines
1. Start off by fitting the two front flexi hoses (041) by screwing them into the front brake callipers, the
other end can then be secured with the nut and star washer to the front of the chassis just ahead of the
upper damper mounting pointing towards each other making sure not to twist or kink the hoses.
2. Next mount the front 3way union to the front upper chassis cross member (there should be a hole for
this in line with the right hand steering rack mount) with the unions pointing left, right and down.
3. Run the front left brake pipe F3 from the left of this connector behind the top cross member then up
and over near the end weld gently bending to suit without kinking to meet the flexi hose, connect up
to the hose and secure the pipe behind the cross member with two plastic “P” clips. Repeat with the
shorter right hand pipe F4 and secure with a “P” clip if necessary.
4. Next fit the second 3way union on the inside of the angle chassis tube near to the master cylinder
where there should be a 1/4” UNF taped hole (the union needs to be in line with the chassis with the
third outlet pointing up and back).
5. The rear inlet of the union needs to be connected to the outlet on the end of the servo with pipe F2.
Pipe F1 then connects from the master cylinder to the side inlet on the servo.
6. The front outlet connects to the front 3way union with F2 this can be run either through or over the
chassis engine mount and secured with two more “P” clips. Finish the front end pipes by fitting the
brake lamp switch in the spare point in the 3way union nearest the master cylinder.
Rear brake lines
1. Start by mounting the rear 3way union on the Panhard rod mount on the rear differential pointing
left, right and rearwards.
2. Use the rear facing union for the right hand brake line R2. Screw it into the union then gently bend
it to follow the diff tube towards the left then over the differential securing by the three of the metal
“P” clips. Carry on following the left diff tube and secure again with a “P” clip in the rear of the tie
bar, mount the pipe can then turn rearwards and into the brake calliper. Do the same with the shorter
right hand pipe R3 using the right hand outlet.
3. Take the third flexi hose and connect into the last point on the rear 3way union. Pass the other end of
the hose down and under the Panhard rod and secure through the bulkhead (there should be a hole in
the right hand side at the base).
4. Secure here with the nut and star washer supplied.
5. The last pipe R1 connects this flexi hose with the rear connection on the master cylinder and runs
from the flexi along the top of the lower chassis rail then to the outside of the rail until it gets to the
front and curls up to the master cylinder. We suggest trial fitting this pipe and drilling for the plastic
To Next Page
Loading...