X reg Ka (2000)

2002 - Had standard rear drums and Hi-Spec 4pots up front
2003 - Take the Ka off the road and fit focus rear discs, car laid up for 5 years without brake fluid
2008 - Fitted a different engine and tried the brakes, pedal is hard but when the engine is running the pedal hits the floor and requires pumping to get it to brake

I've fitted a brand new master cylinder and bled the brakes twice but still have the problem, is it likely I need to change the seals in the front/rear brakes or bleed them again?

Can I test the brakes individually to see if any seals have gone?

Cheers!

 

The engine is a Vauxhall not a Ford

Orange is the vac hose connecting the servo to the plenum (both tight)
Blue is a feed off the main vac hose into the vacuum box
Green is the feed from the vac box into the plenum solenoids


Highlighted in red is the take off for something I've removed (EGR/secondary air, don't remember which), I've put my finger on the end and it doesn't seem to make a difference




When removing the vac hose from the servo you can hear a hiss for a second which suggests a vacuum was created when the hoses were plumbed in, when the main vac hose is removed the pedal is hard and does not operate the brakes, when it is attached the pedal is soft as sh*t

Help!!

 

standard master cylinder might not be big enough for 4 pots up front and rear discs

 

I'd kind of hoped it would be lol, I'm trying the Ka peeps to see what they're running

I'd rather have my cock stapled to a table than run drums on the back again!!

 

When I ran Puma racing calipers up front and st170 rear set up, I got a pedal box fitted

this is was very good with a very hard pedal with full braided lines

 

Pedal box is going to be the fix if I can't work out what's going on, I really don't want to spend the money on it at the moment

I jack the car up and take the wheel off to do bleed it, someone's suggested they it may be fitted with a load valve and need to be bled on the ground?!?