Rebuilding Services in Adelaide

About This Service

When a brake component fails on a modern vehicle, replacement is usually the default — the part is available, the cost is predictable, and it is quicker than reconditioning. But there are situations where reconditioning is not only the better option, it is the only option: when the part is no longer manufactured, when the replacement part is of inferior quality to the original, when a classic or historic vehicle requires a period-correct component, or when the original unit has a feature — bore size, porting, pushrod geometry — that a generic replacement does not replicate.

All Clutch & Brake has been reconditioning brake and clutch hydraulic components in Adelaide since 1984. Over those four decades, we have accumulated a stockpile of old units, discontinued seal kits, and hard-to-source parts for applications that have been NLA (no longer available) from mainstream suppliers for years. We recondition calipers, master cylinders, slave cylinders, wheel cylinders, and brake boosters — on vehicles ranging from pre-war classics to current models where reconditioning is simply more economical than replacement.

Hydraulic Component Reconditioning — Calipers, Master Cylinders, and Wheel Cylinders

The reconditioning process for every hydraulic brake component follows the same sequence: full disassembly, degreasing and cleaning of all metal parts, visual and dimensional inspection of the bore, honing or machining of the bore surface to the correct finish, replacement of all rubber seals and dust boots with new parts, reassembly, painting of the external body, and bench pressure-testing before the component is returned or refitted.

Master cylinders: the primary hydraulic component in the braking system. Master cylinders fail when the internal piston seals (primary and secondary cups) wear or swell, allowing fluid to bypass the piston. A reconditioned master cylinder with correctly fitted new cups and a correctly honed bore will perform identically to a new unit. We recondition tandem master cylinders (the standard on post-1967 vehicles) and single-circuit master cylinders on older vehicles.

Wheel cylinders: the hydraulic actuator in drum brake systems, mounted inside the drum behind the brake shoes. Wheel cylinders fail through a combination of internal corrosion of the cast iron bore and deterioration of the rubber cups. A seized or leaking wheel cylinder causes uneven rear braking and fluid contamination of the brake shoes. We recondition wheel cylinders across all bore sizes used on Australian passenger vehicles from the 1940s through to current drum-brake rear axles.

Slave cylinders: the hydraulic actuator in the clutch hydraulic circuit. External slave cylinders (mounted on the bellhousing) are straightforward to remove and recondition. Concentric slave cylinders (CSC) mounted inside the bellhousing are more involved — we assess whether reconditioning or replacement is more appropriate based on bore condition and whether the transmission needs to be removed for access.

Stainless Steel Cylinder Sleeving — A Permanent Solution for Corroded Bores

Cast iron brake cylinder bores corrode. On vehicles that sit for extended periods, are stored in humid environments, or have had water contamination in the brake fluid, the bore surface develops pitting that a standard hone cannot remove. Pitted bore surfaces destroy rubber seals rapidly — the seal may hold for a few months after a standard recondition before failing again because the bore surface has microscopic surface damage that cuts through the rubber on each stroke.

The solution is to press a stainless steel sleeve into the existing bore. The machined stainless sleeve is interference-fitted into the cleaned and bored cast iron housing — it cannot corrode, it provides a perfectly smooth bore surface for the new seals to run against, and it maintains the original external dimensions of the component. A stainless-sleeved cylinder will outlast the vehicle it is fitted to.

Stainless sleeving is particularly valuable for classic and historic vehicle components where the original part must be preserved for authenticity. Replacing a period-correct master cylinder with a modern equivalent changes the pushrod geometry, pedal ratio, and in many cases the brake bias — all of which affect how the vehicle behaves under braking. Sleeving the original component preserves all of these characteristics while giving it an indefinite service life.

Brake Booster Reconditioning — Vacuum and Hydraulic Units

Brake boosters amplify pedal force before it reaches the master cylinder. A failing booster makes the brake pedal extremely hard to depress — you are effectively braking without servo assistance. The failure modes differ depending on booster type:

Vacuum-assisted boosters (single and dual diaphragm): the most common type on post-1970s passenger vehicles. Uses engine manifold vacuum to assist pedal effort. Failure is typically caused by a perished diaphragm (allowing air to leak through the booster), a failed check valve (causing vacuum loss when the engine is not running), or a worn reaction disc that changes the pedal feel and modulation. We recondition vacuum boosters across all diameters used on Australian passenger vehicles — 7", 8", 9", and 10" single and dual units.

Hydraulic boosters — VH40 and VH44 Hydrovac units:

Used on various older vehicles, factory fitted where more braking performance was required. The VH40 (smaller bore, lighter vehicles) and VH44 (larger bore, heavy commercial) are Bendix-designed hydraulic servo units that use power steering pump pressure rather than engine vacuum. Failures include worn internal piston seals, contaminated fluid, and scored bores. We have serviced and reconditioned VH40 and VH44 units for over 30 years and hold a stock of parts for units that are no longer supported by mainstream suppliers.

Not sure if your booster is failing or if the problem is elsewhere in the brake system? Bring the vehicle in and we will test it on the day. Most brake booster failures produce a characteristic hissing sound from the engine bay when the brake pedal is depressed — a sign of diaphragm perforation or a failed check valve. We can diagnose this in under 30 minutes. Call All Clutch & Brake on 08 8277 8122

Pricing Guide

How Much Does Rebuilding Services in Adelaide Cost?

Prices are a guide only. Final price depends on vehicle make, model, and parts required. Contact us for an exact quote.

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