Category: Brakes

Two years ago, a fellow Delorean owner had one of the original brake hoses fail. The hose was acting as a check valve, so when the brakes were applied, the caliper would not retract. I helped the owner replace his front hoses to fix this issue. I had also read about other problems with the original brake hoses. Looking to avoid any problems, and desiring the firmest brake pedal possible, I decided to replace my original brake hoses.

My car club’s spring tech session was hosted at a local repair shop, where we had a car lift available. This was my best opportunity to get all four of hoses replaced.

Disconnecting and re-connecting the hoses on an automatic transmission car for the back wheels is a major PITA. The transmission being in the way makes access very difficult. Being at a repair shop, I could borrow the metric crowfoot flare nut wrenches and extensions needed.

I didn’t get many pictures because I was focused finishing before we had to leave the shop.

New Hoses:

Installed:

Old hoses:

After getting everything installed, and bleeding the brakes, I found brake pedal was still soft. At home, I made sure all the connections were tight, bought some more brake fluid, and bled them again. This time the brake pedal is the firmest it’s ever been!

Costs:

For years, I felt the brake pedal on my car traveled way too far. I replaced components, bled the system, and doubted every part of my work. It was suggested at the Fall Tech Session that I adjust the rod on the brake booster. After removing the master cylinder, and wedging a length of 2×4 between the brake pedal and my driver’s seat, the adjusting rod becomes exposed. While holding it with locking pliers, loosening it with some PB Blaster and an 8mm wrench, I was able to free it.

Here’s the adjusting rod removed:

I used increments of about 1/8 of an inch, to extend it, remount the master cylinder, and test the brake pedal travel. Finally I got to about 2 inches of travel before any brake pressure is felt. I used a little blue loctite on the threads once I found the sweet spot.

For the first time in many years, the brake pedal in the car feels very firm.

I found out my reservoir was causing a fluid leak, and not the Brake Master Cylinder after all. I was able to find a brake master cylinder with reservoir at NAPA for over $314, however opted not to buy it. Similar new units on eBay were around $200. DMC Europe sells a new Reservoir, but I decided against overseas shipping and currency conversion. I tried to find a better deal. Sure enough, Amazon turned up this gem:

The Centric unit “Includes Reservoir And Cap, Brake Sensor Switch.” I choose free shipping, and waited about a week for it to show up. It arrived, and sure enough, the Brake Master Cylinder did *not* include the reservoir! I sent it back for a full refund. I lost about 2 weeks with that purchase. The price has since been raised more than $25.

I explored a few local salvage yards without any luck. Then, miraculously, I was able to purchase a NOS Girling Brake Master Cylinder with reservoir on eBay. Here’s the unit I purchased:

My D’s reservoir and the new reservoir compared:

My old yellow tank’s build date is between 1978 and 1980. The new tank looks to be made sometime around 1983 or 1984.

I installed the new(er) tank with my old cap, all mounted on my new brake master cylinder. It held fluid! No more leaks!

I ended up reselling the NOS Girling unit (without the reservoir) on eBay.

While waiting for my Girling unit to arrive, I also went on a buying spree and bought another Saab Reservoir and a complete Saab Brake Master Cylinder with Reservoir on eBay.

The Saab reservoir would need different grommets since the tank connections are larger. Also, there aren’t any mounting points for the Saab reservoir. My old unit left, Saab unit right:

I also found a local parts store that carries Castrol GT LMA, albeit the 12oz bottles.

Now I’ve got lots of spare parts. Hopefully I can sell some more on eBay:

Costs

So far, $83.65 to find a working reservoir. Hopefully I can recover some more money if I sell some parts on eBay.

Projects Completed:

• Install Transmission governor clamp
• Change Final Drive oil
• Change Transmission Oil
• Change Engine Oil
• Install Dynamat
• Replace rusted ground bolt on rear bulkhead
• Replace fuse in headlight switch
• Added Dynamat
• Replace Brake Master Cylinder
• Replaced last two 30-year-old coolant hoses
• Unblocked my air ducts
• Flush the coolant

To do:

• Replace leaking Brake Fluid Reservoir
• Bleed Brakes
• Put all interior pieces back in
• Replace fuel pump
• Replace fuel pump boot

Here’s more pics. I should buy stock in Castrol:

Filling the final drive:

Cleaning the reservoir, new Brake Master Cylinder ready:

New BMC and old reservoir:

Bench Bleed kit:

It now appears the reservoir is leaking, and possibly the old BMC wasn’t…

Unsuccessfully bleeding the system, still leaking fluid:

Bleeding the calipers:

I added up all the receipts I had, and guessed on the other items: