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Today at Atelier Kaz - Private NSX Enthusiast, ex-Honda R&D engineer with F1, Indy/CART background

Eng Refresh, Health Check, etc 37

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Front brake calipers were removed ages ago but in order to finish the engine tasks first, left them until recently.

Normally, when the owner has arrived at my place, I go through each wheels/tyres/body work while the owner is standing at the side of the car.

I already knew there was at least one issue with the FL brake as there were excessive amount of rust left on the disc despite the owner driven several 100s miles getting to my place.

Also, when I tried moving the car into the garage, immediately I felt strange feeling at the brake pedal.
Later, carried out the standard method for testing the master cyl and confirmed that it was leaking as the pedal sunk.

From the paint lock marking, surprisingly, this master cyl is most likely the original one from the factory.
I can't remember the last time I struggled so much separating the master cyl from the booster cover.

Due to excessive rust, it was bonded together.

Finally it came off and no surprise, full of rust and leakage.

Fortunately, the area behind the seal was not chewed in by the rust and still smooth flat so I should be able to make good vacuum status with the new master cyl.

Should have adjusted the white balance so you can't see well in this photo but you may be able to see the wet marking/film left on the shaft as well as where the pushrod sleeve sits.

Cleaned to this level and will coat the area with thin film of silicone grease.

Please replace brake fluid regularly.

One of its job is to convert the moisture into chemical substance to prevent the vapour lock and slows down the rusting of internal metal parts.
However, if you don't drive the car regularly and left the brake fluid without changing, it will cause all sorts of issues.

You should not see rust on the fitting where it is hidden inside the master cyl body.

It is recommended to replace both the pad and the disc at the same time.
Looks like the front brake pad was replaced but not the disc when it was dealt with last time.

Front brake pad has so much material left so not cost effective replacing now but looking at the ridge of the inner disc surface,
it is at/near its limit so once the existing front pad worn for a bit more, please replace the disc and pad as a set.

Please remember that you only have about 2mm for wear limit so even without using the micrometer, you can easily tell its limit if you can see ridge at the edge.