Initial 6-14-02, Last Revised 7-16-02

The PDWAs I've found in the TR250s and early TR6s use cup type seals that apparently are no longer
available. The PDWAs that I've found in the later TR6s use simple O-Ring seals. The photo below
shows the components of the PDWA. (A description of the PDWA operation and overhauling the PDWA
are in the first two Brake Notes listed at the end of this note.)

The two types of PDWA pistons I've

found are shown on the right. The
early type with the cup seals is
above and the later type with the
O-Ring seals is below. Both pistons
fit into a 5/16" bore in the PDWA
brass casting. [Many use the term
shuttle rather than piston. The
only reference I found was in a
Haynes manual where it is called a
shuttle valve. One thing is sure, it
is not a valve so I decided to stick
with piston rather than risk
perpetuating that misinformation.]
Since the cup seals are no longer available, many of us have been using the PDWAs from the later TR6s
as replacements for the early PDWAs. Unfortunately, that supply seems nearly exhausted.
Replacement PDWAs are available but are of a different style (cast iron or steel instead of brass) and
cost nearly $200 with a new switch (the old switch won't work).

I decided to fabricate some of the later type pistons and use them
in my early PDWAs. The one thing that bothered me was the
very narrow part of the piston where the the switch plunger rides
--- see photo on right. I was afraid that I'd break the piston as
soon as I turned it down that small (~ 0.10") However, upon
closer inspection, I decided that there was no reason that the
center part had to be that narrow. The only requirement seems to
be that the step up be about 0.05" to operate the switch. Of
course, if the diameter is too big, the switch will be on even if the
piston is centered. One solution is to reduce the length of the
switch plunger. An easier solution is to merely put a 3/8" ID flat
washer between the switch and the brass casting --- that will raise
the switch about 0.60" to compensate for a thicker piston.

The photo on the right shows the OEM piston on the

top and the substitute I fabricated on the bottom.
The substitute seems much more robust to me. It
was also much easier to turn. I used 5/16" drill rod
and finished the piston with Gun Blue. Most the
cuts were made with a 0.060" wide cutoff tool. I
ground a special tool to turn the sloped sides of the
area that operates the switch. I used that tool after
an initial cut with the cutoff tool. After the turning I
smoothed all edges with a fine file. In one case the
piston hung up in the casting. A second spin in the
lathe and the application of a file fixed that. The
photo below shows the partially machined piston in
the lathe.

The piston is symmetrical around the middle. Mark Riddle of Asheville, NC generated the following
drawing with all the required dimensions (all dimensions are in inches). Thank you Mark!

All that is needed to complete the job is a couple size #008 (3/16" ID, 5/16" OD with 1/16" cross
section) Ethylene Propylene (EP/EPR/EPDM) O-Rings. I tested the switch to see if a washer was
needed by centering the piston and screwing in the switch. If the switch is on, a washer is needed, if it
is off no washer. I then moved the piston off center and verified the switch operated. I needed a washer
under one switch and no washer on a second switch. (That second switch wouldn't have operated with
an OEM piston.)
Liability risk prevents me from fabricating a batch of these for the TR community. You might try a local
machine shop or vocational school, etc. This is also an excuse to buy your very own lathe. It will pay for
itself in no time at $200 savings per PDWA.
Links to other notes on Brake Theory & Overview
TR250 & TR6 Brakes: Overhauling Brake Master Cylinder & PDWA
Overhauling Brake Servo
Overhauling Pedal Assembly
Overhauling Front Brakes
Overhauling Rear Brakes
Overhauling Handbrake
Overhauling Brake Pipes
Selecting Brake Fluid
Bleeding & Adjusting Brakes
Troubleshooting Brakes

Extracted from Buckeye TRIUMPHS Technical Page

[Authors name removed by request]