My mate has put servo assisted brakes on his mk3, new servo, bar/linkage from pedal (accross buldhead to passenger side) and master cylinder.

he now only has about half travel on the pedal and very little if any brakes.

all been bled and liquid is nice and clear and air free.

it sounds like something is bottoming out in the master cylinder, and when u remove the cylinder from the servo you have full travel on the pedal.

i spaced the cylinder off the servo and that got a bit more travel out of the pedal and gave some brakeing.


now whats happening is the brakes will stop the wheel spining when the pedal gets just above where it stops runs out of travel.
at this point (pedal pushed hard down) the wheel frees up again and you can turn it.


the master cylinder is brand new, but i cant see it being anything else causing the problem.

Anyone else had any similar problems that was caused by faulty master cylinders??

 

bttt

 

think ive sussed it mate, the adjustment we found on the servo, i think it need setting as i notice were getting slight brakes and loosing pressure because the master cylinder isn't closing so it losing the pressure at the calipers causing us to lose brakes? so 2moro im going to remove the master cylinder and do a few measurements and try re setting it all and see what luck i have

 

Is the servo vacuum assisted ?

 

the servo is a vacuum assisted servo but the engine aint running yet as ive turned my attention to the brakes

 

it is but like said not connected at the moment. could that cause problems?

 

cowboi go out to your car, test the brakes with no igniton on and tell me if you notice the difference

get the air line feed for the servo from simons car running and plug it into the escort and see if that helps

thought hat said you should still be able to lock the brakes with no engine running put pedal will feel tougher than non servo assisted brakes

 

i know the brakes will be different with no servo, but wasnt sure if the vacuum pipe hole being open would stop them from actually working.

the brakes wont pump up or anything on his car, there is definately something wrong somewhere.
i think its a faulty master cylinder.

and whats really weird is that they stop the wheel but then let off after, its as if the master cylinder is letting the fluid back into the resevoir and releasing the brakes.

also its not giving full travel on the pedal, and sounds like it bottoming out when u push the pedal (a metal on metal knocking sounds when pumping the pedal)

im gonna see paul later and i'll tell him to take the cylinder off and see if he can moce the piston by pushing a screw driver in it.
ive got a feeling its going to be seized.
they are easy enough to take apart but he had so much trouble getting that one that i doubt he'll get a rebuild kit for it.


any way mate, how u been??

 

imm sure ive got a erst master cylinder brand new at work on the shelf, ive got 200 seperate types on there the last time i had to check a issue out

has he got a ABS one or is it a non ABS one ( 4 outlet is abs if i rember)

ill find out monday if i get time as im in the middle of seting up a new jap product range aswell as covering for being short of staff so cant promise but ill find out if i get time

 

been up to all sorts these days, gym 4 times a week, kick boxing 1 day a week, working 6 days a week, hangovers killing me for 2 days in a row, trying to finish that fucking kitchen, house hunting, trying to spend time with the missus and little one aswell so aint got much time to be on here and even loaf about like i used to

 

ive checked the master cylinder today, a can remove it from the servo push it with an extension bar etc and no brakes, open a bleed nipple whilst pushing it and only a drizzle?

 

maybe its the wrong one for the set up u have paul.

possibly wrong linkage from pedal, or servo or the rod coming through the servo.

something is wrong mate and if ur cylinder is ok and the correct type im guessing its the setup as it shouldnt be bottoming out, and the cylinder is stopping u having full travel in pedal.

cant be anything else is the cylinder is working and the right type.

what servo and linkage do u have? are they right for each other?

 

i have a s2 linkage and servo, the master cylinder moves yet it doesnt operate the brakes?the fluid that comes out the bleed nipple doesnt have enough pressure to push brakes i wouldnt have thought?

 

Are you running the inline pressure reducers ?

 

sorry to sound thick mate but what are these? are you on about the balancing valves on the inner wing? if so then no, but i have balancing valves either side in the inner rear arches, cheers

 

Are you plumbed dual cross diagonal or front/rear ?

Sorry for all the questions Im filling in your gaps

 

btw if you need one at some point ive got a brand new mk4 steering rack at work for about 20 quid plus vat

 

they are plumbed diagonal, i. e- front passenger and rear drivers run off the same t piece, cheers

 

dont need one at the mo, but cheers mate, u going to rs central?

 

If you can then try re plumbing it front / front and blocking off the rears.

If you get a pedal then we are getting somewhere.

 

dont need one at the mo, but cheers mate, u going to rs central?