Randy,

How did you hone the bore?

Dan


> On Aug 5, 2015, at 5:41 PM, Randy Bennell via Mercedes 
> <mercedes@okiebenz.com> wrote:
> 
> I ordered a rebuild kit for the mc in my 1976 115 300D.
> It took a while to show up but I got it. It is Raybestos brand and says that 
> it was made in Australia.
> I am struggling to get the kit installed however. It was a bit of a bear to 
> get apart and is also challenging me in putting it back together. No problem 
> taking the mc out of the car.
> It is amazing how stretchy the rubber parts are. Even after the Lord only 
> knows how long the existing parts had soaked in brake fluid, they were not 
> easy to get off of the metal plunger. It took some prying to get them off. 
> Then one has to stretch the new ones onto it. Not easy. I cut the nozzle off 
> of a big caulking tube and used it to slide the rubber cup up on over the 
> ridge on the metal plunger. I tried to just roll it on with my fingers but 
> that is not easy when trying to do it to a small rubber doodad soaked in 
> brake fluid while wearing rubber gloves. Using the nozzle from the caulking 
> tube permitted me to stretch the rubber cup up to about the size of the metal 
> plunger diameter so that I could slip it over the ridge into the groove. 
> While doing so, I hoped I was not doing it any harm.  I guess, time will tell.
> 
> Now that I have that part together, my next challenge is to get that plunger 
> with the rubber cups on it to slide into the bore on the mc casting. There is 
> no way to do it with one's fingers as the smaller bore is at least 2 inches 
> down inside the larger bore on the stepped housing. I think the answer is to 
> find some tubing the right size and slip the plunger into it and reach the 
> whole mess down inside and get it lined up with the bore and then push the 
> plunger out of the tubing into the bore. I measured the plunger and it is 
> .749" so pretty close to 3/4" and 3/4" inside diameter pipe ought not to be 
> too hard to find. I need to poke around in my junk and see what I can come up 
> with, or head to a hardware store with my digital calipers to see what I can 
> find.
> The service manual on the CD indicates that MB likely provided a rebuild kit 
> for these at one time that came essentially assembled with a new plunger 
> inside a plastic tube. One shoved the tube into the mc housing and just 
> pushed it in. At least that is what it looks like to me in the photos.
> I am not so lucky. I just got a small bag of loose parts in a box. The price 
> was right and the mc looks good so it seemed to me to be a good thing to try 
> to keep the car pretty much original. However, I have paid more in insurance 
> for the period it has been off the road while I waited for the parts and then 
> while it waited for me to work on it, than it would have cost to have a 
> rebuilt one almost immediately. Such is life, "live and learn" hopefully.
> 
> RB
> 
> 
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