Master cylinders - clevis pin installation

[AndyPen]

Old school way of getting pin in.

1. I tie a piece of heavy duty thread through pin hole.

2. Tie a cotter pin or small nail to other end.

3. Align rod and peddle hole

4. Loop thread through hole.

5. Pull thread to pull pin into hole.

6. Cut thread insert cotter pin.

just love the alternative thinking here

[1071 S]

That is because in Australia you don't have curves and declines - no need to brake on endless empty straights*

*stereotypical impression of an Austrian of unknown Australia

But we all know there are no kangaroos in Austria

Cheers, Ian

[MiNiKiN]

But we all know there are no kangaroos in Austria

Cheers, Ian

mostly true, except for a few zoo runaways. And BTW, we neither live in 'forest cities with explosive trees'

[Andrew1967]

Just fitted the re-rubbered NOS brake master to HOY and used an R clip.

Managed to get the clevis pin in using just my finger tips - fiddly and awkward .. I like the modified fork method, bend it back afterwards, replace in kitchen drawer and no-one's the wiser

The R clip I used is small and is a real snug fit around the pin and is barely bigger than the width of the push rod so I really can't see how it could become dislodged. Some clips I've seen are twice as long and I could see an issue there.

Will have a look to see if the ones I fitted to 9748KO in 2006 are still there !

[Spider]

Our local BMC Plant originally fitted Split Pins and later changed to R Clips, P/N MYH1019, which they continued to fit to the end of production.

The R Clips there used though were quite short compared to many that are offered for this job



That's an original R Clip at the top, it's just on 20 mm overall length. The middle one I obtained from Somerfords, I've checked these on my set ups and they are safe. The lower one came from one of the Mini Parts suppliers and is deadly.

I've always used the factory ones and of last, those from Somerfords, never had an issue with any of them.

[SMOKE GREY]

Used R clips for years .

[Andrew1967]

Looks like the clips I have are originals too Chris ...

[Spider]

But we all know there are no kangaroos in Austria

Cheers, Ian

mostly true, except for a few zoo runaways. And BTW, we neither live in 'forest cities with explosive trees'

Isn't 'Austria' just a short hand way or writing Australia ??

From our own backyard

Looks like the clips I have are originals too Chris ...

Yes, spot on, great fitted example of the right clip, cheers Andrew.

[rogerotto66s]

Help!

1966mCooper S - LHD

Steering and heater are now installed and I am trying to re-Install both master cylinders.

While trying to insert clevis/cotter pin it “jumped” into the corner of the little pedal box cutout.
I had to remove both cylinders to retrieve the pin.

Before I start over I thought I would ask if there was a recommended order to accomplish my task.

On my first attempt I bolted down both cylinders first and then did both clevis pins.

Should I start with the brake cylinder and install completely and then move onto the clutch?

Any trick to not allow the pin to “jump” into the corner again!

Thanks in advance.

Note: it was very easy the first time. I must had the heater and steering out. Now there is not much room to move around.

[winabbey]

Any trick to not allow the pin to “jump” into the corner again!

A magnetic tool would've helped retrieve the pesky pin when it dropped in that cavity, and can assist in positioning the pin for insertion.

Magnetic Tool.jpg

There's also a tool to hold the clevis pin for easy insertion.

Minisport 2375.jpg

... or a table fork can be borrowed and used (when the custodian of the cutlery drawer is not looking).

Clevis Pin Fork.JPG

[111Robin]

In a similar vein I find the use of one of these claw tools to be just the job for the clevis pins, with the pin held perpendicular to the tool it can be fed into the most inaccessible spaces. The Elan pedal box is even worse then the Mini so I am going through the same exercise at the moment.

[rogerotto66s]

Thanks for suggestions re: clevis pin insertion.

#1 I do have the magnetic tool was able to retrieve the pin numerous times ... but ... the last time required the removal of the brake cylinder to retrieve the pin from the far corner behind the brake cylinder.

#2 I have been using the bent fork and also the magnetic tool to attempt to position the pin. No luck so far. I will be trying again today. Need more room or smaller hands!

#3 I will also be trying the thread (dental floss) approach to pull the pin through.

#4 I may also try the 5/16” bolt and washer approach as well.

Still my original question was with regard to the order in which to do things (to maximize likelihood of success).

I look forward to your direction.

[Peter Laidler]

Don't even bother to work down there without first doing 3 VERY simple jobs.
1) Remove seat - 2 nuts and bolts, put seat in back of car
2) Centralise steering wheel/column, remove steering column assembly - unclip electrical cable block, and 2 nuts and bolts
3) Disconnect intake hose from heater, unhook hheater from bulkhead and allow to drop to left side of floor
Time taken, 10 minutes.

Immediate access to everything. I use a vacuum cleaner hose to suck out anything that's dropped in the cossmember.

No need to use a fork if you do all this, evverything is easy accessible

[rogerotto66s]

Thanks for the info Peter.

Seats have yet to be installed.

I like the vacuum tip. I should have thought of that before I removed both cylinders.

I will try the brake cylinder and if unsuccessful I will drop the heater and then remove the steering column.

I will report my results.

[Andrew1967]

Having this week fitted the clevis pins to the master cylinders of my Mk2 Cooper, I'd agree 100% with Peters advice .. will make life SO much easier. That said, I didn't resort to removing the column, just the seat and heater.

I used a pair or needle nosed pliers to get the pins into place and then, (dare I say it), also to fit some (very well fitting) R clips that won't come out ... well they haven't in the past 20 odd years anyway.

[Peter Laidler]

And when you're about to put it all back together Roger, don't forget to spray preservative deep into the ends and middle section of the bulkhead crossmember

[rogerotto66s]

Both clevis pins are in . Hooray!
Now the split pins are up next.

I did remove one of the seat brackets. This made it more comfortable when lying on my back.
I also removed the LH heater ear and the LH plastic heater demister tube.
The steering wheel stayed in place as did the heater.

I also used the “bent fork” approach as well as a needle pliers.

I also tied a piece of dental floss to the clevis pin.
This really helped in retrieving the clevis pin whenever I dropped it.

A66720AD-E460-4A60-8194-E00A955CDAF7.png

Last tip I used was to attached a plastic cable tie to the end of the split pin.
This really helps when taking things apart. Just pull on the cable tie with needle nose pliers
and the pin easily come out.

03A9DB55-F52F-464D-9CA1-1DF5D9C3B004.jpeg

Thanks everyone!

Next up : reinstall brake servo.

[Peter Laidler]

Servo fitting and plumbing. Can I respectfully make another suggestion Roger?

Before you fit the servo, plumb the brakes in using a small bit of brake pipe direct from master cyl to the 3-way junction (it's a bit longer for you with a LHD car!). Have servo pipes handy. When you know that the brakes are working well, THEN connect up the servo pipes after a week of testing. If something ain't right after that, you know it's the servo and not the hydraulics

[agricola]

A thought I have had is to drill a small 1 mm hole up the centre preferably in a lathe attach strimmer cord with a knotted end through the centre so you can pull the pin through. Remove cord.
I know somebody is going to say you are compromising the pins strength but for a 6.25mm pin in shear I personally doubt it. But I personally would use a home made en24 pin but I am sad and like lathes....
PS I was chatting to a Brabham single seater fitted with a cosworth FVA owner at Donnington he had drilled all the 7/16 bolts on the wishbones to save weight and quite a few were in single shear ...

[agricola]

ops arent the pins 5/16 7.9mm?