Master Cylinder Plug, Fits Type 1 Beetle 46-66, Sold Each

OVERVIEW

In the world of vintage air-cooled Volkswagens, the integrity of your hydraulic system is paramount, and often the smallest components are the most critical. This EMPI Master Cylinder Plug is a vital restoration piece designed specifically for early Type 1 Beetles and Karmann Ghias. Its primary function is to provide a liquid-tight seal between the master cylinder body and the brake fluid reservoir feed pipe. Over decades of service, the original factory rubber components are subjected to extreme temperature fluctuations and the caustic nature of brake fluid, which inevitably leads to hardening, shrinking, and catastrophic cracking. A compromised plug allows air to enter the lines or, worse, allows fluid to weep out, potentially damaging your vehicle''s chassis paint and compromising your stopping power when you need it most.

Crafted to meet or exceed original equipment specifications, this plug (OE Part Number 113-611-817) features a precise 15mm outer diameter designed to snap perfectly into the master cylinder port. It is the exact replacement required for our popular replacement master cylinder, part number 113-611-021C. Whether you are performing a concours-level restoration on a split-window Beetle or simply maintaining your daily-driver 60s Ghia, replacing these rubber seals is a mandatory step during any brake system overhaul. Don''t risk your safety by reusing 50-year-old rubber; ensure your reservoir lines are seated securely and your hydraulic pressure remains consistent with this high-quality, oil and fluid-resistant rubber grommet.

FITMENT

• Volkswagen Type 1 Beetle (Sedan or Convertible): 1946, 1947, 1948, 1949, 1950, 1951, 1952, 1953, 1954, 1955, 1956, 1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966
• Volkswagen Karmann Ghia (Coupe or Convertible): 1956, 1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966
• Compatibility Note: Specifically designed for early single-circuit master cylinders utilizing a 15mm bore for the reservoir feed.

SPECS

• Part Number: 113-611-817
• Manufacturer: EMPI
• Material: High-density, brake fluid resistant EPDM rubber
• Fitting Diameter: Fits master cylinders with a 15mm bore OD
• Overall Outer Diameter: 17.50mm (at the sealing flange)
• Inner Diameter: 4.5mm (designed for a tight grip on the reservoir feed pipe)
• Quantity: Sold Each (Note: Single circuit cylinders typically require one, but always check your specific configuration)
• Color: Black

PRO TIPS

1. Proper Lubrication is Key

When installing the metal reservoir feed pipe into the new rubber plug, never attempt to press it in dry. Forcing a dry metal pipe into new rubber can cause the plug to tear or, more commonly, push the entire plug through the hole and into the master cylinder body. Use a small drop of clean DOT 3 or DOT 4 brake fluid to lubricate the inner diameter of the plug. This allows the pipe to slide in smoothly while maintaining the necessary tension for an airtight and watertight seal once the fluid dries.

2. Prep the Metal Feed Lines

Before installing your new EMPI plug, take a moment to inspect the end of your metal reservoir feed line. Because these lines are often exposed to the elements, they can develop light corrosion or pitting. If the metal surface is rough, it will not seal correctly against the new rubber. Use a bit of 400-grit sandpaper or a fine Scotch-Brite pad to polish the end of the line until it is smooth and shiny. This ensures that the 4.5mm inner diameter of the plug makes full, 360-degree contact with the pipe.

3. Seat the Plug Before the Pipe

Always install the rubber plug into the master cylinder bore BEFORE you attempt to insert the metal feed pipe. It is much easier to ensure the 15mm groove of the plug is properly seated in the master cylinder housing when you aren''t fighting the tension of the feed line. Once the plug is "snapped" into place and you have verified it is flush against the cylinder body, then you can carefully guide the lubricated feed pipe into the center of the plug. This sequence prevents the plug from distorting or seating at an angle, which is the leading cause of leaks in early VW brake systems.