Brake MC rebuild kit/rebuilder

2002turbo

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Replaced brake MC with OEM part (Germany) as brakes were binding and MC appeared to be leaking a bit. Now we are having trouble with pedal travel, we think the fluid is bypassing the seal in the new MC. WN seems to be out of stock of this variant (74 CS, later car). So if our diagnosis is correct, we are going to need to replace at least the seal in the new MC. And while we are at it, I would like to have the old MC rebuilt so I have one in 10 years when they are completely unobtainable.
 
The only Master available is from the e12 today but is the same as the 2800CS without the rear drum proportioning valve. I used one in my 3.0CS and it works fine. Walloth had the seals but any brake shop can rebuild these.
 
so where does the brake shop get the seal kit? Around here if it's metric you run out of options pretty fast.
 
#()#+ ... I have a lathe like that, made in Taiwan, the spindle is metric diameter with an SAE thread pitch.
 
OK well it seems the problem is the master cyl we replaced was the smaller diameter version and that was not correct (it was a new OEM cyl) .. so that is now available for someone who needs one.

But we need the seal for the original MC that we pulled out, the mechanic says "it's just under an inch" ... so I assume it's a 15/16". The obvious sources around here don't seem to have it. Any help would be appreciated.
 
Well we tried that (with a new "small" OEM MC) and we got very long pedal travel and inconsistent braking. It's possible there is some other problem but the rubber hoses and calipers are new as well. The rear proportioner was gone through and cleaned out (some gunk in there). Some metal lines were replaced. No leaks that we can find. So we are back to the original "large bore" which we are honing and then we will replace the seal, if we can find one.
 
Getting nowhere searching for seal kits in the USA, found some kits on ebay were close to $300, so I went to WN and they have them. I ordered 5 kits for the 23.8 cyl to spread the rather stiff shipping cost. I will offer them to people who are similarly frustrated at a modest markup, once I know the UPS tariff etc. Circa $100 shipped CONUS is my guess.

If someone is stuck with a small dia cyl, I have a virtually new unit OEM that we installed and then had to uninstall.
 
Well WP needs $400 to rebuild a MC ... meanwhile the package from Walloth finally showed up, along with a demand from UPS for an additional $110!!

So I ordered 5 rebuild kits pn a34311103740 supposedly for the large (23,7mm) MC, see photos. I can spare you the pain (and 3 week wait) at $100 per kit post paid within the USA. That's far less than the cost of buying a kit from Germany, considering the 50 Euro shipping charge and the UPS add-on (which probably reflects a brokerage fee, not just the tariff which is supposed to be 10% from Europe.)
 

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I got a copy of the customs declaration, the fools at UPS classified these parts as steel parts subject to 50% tariff ...
 
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