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Before I go pulling the brake system apart I need some info, After fitting Hi-Spec 4 pots and a rear disc conversion on my cabby and after bleeding them, I now have the pedal going straight to the floor when the engine is running, if I turn it off and pump the pedal the pedal goes hard but when held down and start the car it goes back to the floor slowly. Now I thought it was the servo but after leaving it for a day I went to remove the servo vac pipe and it had held vacuum so now i'm not 100% sure.


Also is there anywhere that sells master rebuild kits????



Cheers


Ginger


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Sounds like your seals in your master have flipped.

When you bleed a old system with a used master cylinder the pedal stroke goes to the floor and the seals go past their working stroke into a rough part of the cylinder and flips the seal.

So i would fit a new master not a seal kit.

 

Are the rear calipers positioned so the bleed nipple is at the top when bleeding them?

 

Clamp all 4 flexi pipes and try it again, if the symptoms are the same,
Will help narrow down if its a master or caliper fault
If you've put larger calipers on front and changed to discs on the rear,
Your possibly needing a larger master to displace more fluid

 

I thought the seal might have flipped so went out and pulled it apart and they were ok, little bit of wear on the furthest forward piston though.



No, with the position of the calliper the bleed nipple is between 8 & 9 o'clock with the hand brake cable coming over the top. should the cable be underneath then. Didn't even think of that as I had the callipers labelled left and right from the car I took them off.




I had rear discs and 4 pots on my old XR2 Turbo and ran a standard master and servo for a while, was ok but ended up fitting a Mondeo unit.



Ginger



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Defo try bleeding the rear calipers with nipple directly facing up, i had the same problem used every method of bleeding and had no joy untill turned the calipers

 

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Just swapped the rear callipers over so the bleed nipples are on the top, will bleed the over the weekend, hopeful that,lol sort it.


Cheers for the replies.



Ginger


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Let us know how you get on.

 

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Right, callipers swapped side to side, re-bleed twice all around and still the same, swapped the servo as well and still no pedal. Has to be the master cylinder.

Anyone know of an upgrade, I.E Mondeo, Focus etc. Had a Mondeo non ABS one on my old XR2 Turbo and worked a treat. Not seen anything like that done on an Escort.


Ginger




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The fact the pedal pumps with engine off shows the servo is fine.

Will either be MC or a fuck load of air in the system. How are you bleeding? Gravity/vacuum pump/pressure bleed?

 

Clamp all the brake hoses with brake hose clamps and see if the pedal is solid, if it is remove the clamps 1 at a time testing the pedal each time if the pressure drops you know what corner the problem is on. If pedal is still shite with all hoses clamped it's the master cylinder or a load of air somewhere.

 

dunno if it helps had exactly the same symptoms on my daily a3 after replacing a rear caliper yesterday went on the interweb they said air in master cylinder luckily the a3 has bleed nipples on the master cylinder 5 minutes job done

 

Do you bleed the master first? You must have fluid flow from each union on master first.