ERA 452 -- crushed brake-fluid supply lines

[Exit32]

I noticed a small puddle of brake fluid under my ERA 452. I found a leak in one of the rubber hoses that carries brake fluid from the underhood reservoir to one of the master cylinders under the car. The leak was in a portion of the hose that's routed through the inside the car, against the firewall. The leak was caused by the clutch pedal "crushing" the hose against the area where the floor meets the firewall. It took 12 years to crush it enough to create the leak.

Turns out that both brake-fluid supply hoses showed evidence of crushing, so I replaced both of them. I attempted to re-route the hoses to avoid the clutch pedal, but the retaining clamp under the car seems to make it impossible to change the path the hoses follow from the underhood reservoir to the undercar master cylinders.

While working on the car, I also noticed that the clutch slave cylinder is weeping a little, so I think it's time to rebuild or replace it.

Two questions:

1. Does anyone know of a better way to route my brake-fluid supply hoses to protect them from being crushed in the future?

2. What's the best approach to resolve my slave cylinder drippage?

Your counsel and advice are sincerely appreciated.

-- Dan Somers

Cobra Dream

[mrmustang]

Originally Posted by Exit32

2. What's the best approach to resolve my slave cylinder drippage?

Your counsel and advice are sincerely appreciated.

-- Dan Somers

Cobra Dream

Dan,

Don't bother rebuilding it, replace it.


Bill S.

[vettestr]

The master cylinders most often can be rebuilt but at a cost of 41% of a new replacement ...? Many are made of aluminum and the bore becomes pitted from the moisture/water absorbed by the fluid. If pitted honing the bore for proper seal fit is more difficult but it can be done in most cases.

Making a short steel line for each old rubber line may reduce the diameter enough to stop interference with the pedals as a guess??? Can you get to area well enough to fab steel lines past the problem area, you mentioned re-routing was not an option? You will find a fix I am sure.

[SSSammy]

Dan, the later 731+ cars route these lines from the reservoir along the top of the frame rail and then just at the front of the footbox, they make a 90 deg turn and then another 90 deg turn into the front of the clutch/brake box. They do not go inside the footbox at all. If you want a pic, I will take one for you. But the lines are steel, changing to rubber hose just at the ends.

Good thing they are steel, because they pass about 1" from a header! I don't know if this will ever be an issue, but I wonder ...

Sam

[patrickt]

Originally Posted by SSSammy

If you want a pic, I will take one for you. But the lines are steel, changing to rubber hose just at the ends.

Here's a shot of mine.

[patrickt]

... I'll post a couple more to give you a better idea of the proximity issue to the primaries (no problems yet, tho). And a shot of how it feeds out to the splitter that feeds the calipers.

[CHANMADD]

Those pipes are way too close to the exhaust! You won't have a problem until its too late and you crush the front of the car. Put a stop under the pedal if you have to!

[Exit32]

I really appreciate all your replies, and I'm not surprised to learn that ERA has re-routed the brake-fluid supply lines in their newer cars (thanks for the update, SSSammy). Like CHANMADD, I'm also concerned about the close proximity to the headers shown in patrickt's excellent photos. I can envision boiling brake fluid inside the line after a long cruise on a hot day.

So far, I think the best solution for me is the one proposed by vettestr: "... a short steel line for each old rubber line may reduce the diameter enough to stop interference with the pedals ..." With two short steel lines inside the car, I can create a jog to avoid contact the bottom of the clutch pedal. This solution eliminates the need to drill holes in the brake box under the car and keeps the lines far away from hot headers.

At this point ol' ERA 452 is running fine, so there's no rush for me to tackle this project. If anyone has other suggestions, I'm listening. Guess I'll take mrmustang's advice and order a replacement clutch slave cylinder from ERA, too.

Thanks,

Dan Somers

Cobra Dream

[SSSammy]

Your brake supply lines are rubber, so easy to cut some longer ones and just "S" them to the side a bit so they do not get struck by the pedal.

Sam

[patrickt]

Originally Posted by CHANMADD

Those pipes are way too close to the exhaust! /

That helps boil the moisture out of the lines. Seriously, my previous shot was a little deceptive. There is about 3/4 of an inch between the supply lines and the lowest primary. Here's a better shot:

[strictlypersonl]

The proximity of the tubes doesn't concern me for two reasons:

1/ Heat will tend to rise from the pipes, so only radiant heat is a factor, mitigated by airflow. Note that the plastic-coated metal clamp still looks OK.

2/ Hot fluid doesn't flow into the master cylinder except under rare conditions. Namely, only after a major system leak has already occurred. Otherwise the hot fluid stays over a foot away.

Don't Worry. Be Happy!

[strictlypersonl]

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