A little past midnight here. I just finished installing the new master cylinder, and am pleased to report that it is functioning well. Removal of the old cylinder was a bit involved; especially the disassembly from the pedal structure. That required some articulated ratchet wrenches and one box-end that I modified with the acetylene "hot wrench" to fit the lower nut and bolt that secures the master cylinder to the pedal assembly.
As I was working solo, I circumvented the bleeding process by filling the master cylinder with DOT 4 fluid with a 27 gauge spinal anesthesia needle, and a 10cc glass syringe. In order to avoid emptying the main reservoir when I removed the feed tube, I clamped it with special vascular clamps used in open heart surgery. They occlude the vessel, but do not lacerate it.
Reassembly was essentially the reverse of the above, with the "fiddliness" attending the installation of the nuts and bolts in a relatively tight area. Dismounting the pedal assembly from the floor helped.
I noted with some alarm that the clevis bolt that secures the fork of the actuating rod to the clutch pedal is wearing notably where it interacts with the pedal vertical member. The Clevis does not rotate in the pedal arm, and wears notably where it inserts into the arm. I was puzzled as to why a rod-end bearing was not used in this application, but I suppose it may have something to do with cost. I will be designing a rod-end bearing modification for the clutch and brake applications, and would advise the forum members to be sure that those areas are lubricated frequently. I have a difficult time posting pictures here, but will try to load one of the worn Clevis pin.
Steve, thank you again, and I add that I was mighty relieved that I didn't have to go after the slave cylinder.
