This is as logical a place to start as any. "After the list of other things that have been done why the (expletive) would you open up yet another system?" Yeah.. that's a really great question. It's not because I'm sadistic. You see, I started with the brakes. Long before I discovered the rust-thru on the floors, or learned about the front suspension having window insulation acting as bushings, I tried to fix the brakes. I completely redid them at the wheels. I even replaced the hoses with nice new ones, but I couldn't get the rear's to bleed. Turned out, the master cylinder wasn't pushing fluid to the rear, so it had to go. After some reading, I learned that for some weird flaw of nature the clutch master cylinder fails within 6 months of replacing the brake master cylinder if you don't replace them at the same time. Rather than tempt Murphy's Law, I figured I'd just get after it. Besides, winter was coming so the little car was going into the garage anyway.....
Remove the Brake Master Cylinder (MC)
|my engine bay - before|
Remove Brake Booster?
|not mine, but better angle|
So, how do you get this thing out? You can try starting by removing the pin connecting the brake pedal to the lever. This is a royal PITA. You need inhuman fingers to do this. Same goes for the clutch pedal/MC and even getting the brake booster off. After the fact, I figured out that you don't need to separate the brake booster from the pedal box at this point. You can just remove the booster with box all at once. Whaaa???
Remove the Clutch Hydraulics and Pedal Box
|thank you eBay for your blurry picture|
With the box on your bench, you can easily pull the various parts off. The brake booster is held on with 4 1/2" nuts, and the pin from the brake pedal is easier to get to when you're not leaning over a wing (fender). The clutch MC is held on with 2 1/2" bolts. One of them twists into a fixed nut, the other needs a wrench on the nut on the inside. Like the brake pin, the clutch pin is easier to get off at this point. I found needle-nose pliers to be up to the task.
Now, your pedal box, master cylinders, brake booster and pedals are all apart. In part 2, I'll cover cleaning, painting and re-assembly. Thanks, as always, for following along.