A Bit Of Info/help Needed

[dcc 855]

Hi All

 

Managed to get my 205 to Sandy a few weeks ago, but we noticed a bit of an issue for the brakes. The brake pedal does not want to return to the height it started, prior to being pushed.

 

Yes I have fitted bigger brakes and a bigger MC but now the pedal just 'sticks' to the floor!

 

The brake setup is:

 

23mm master cylinder

206 gti 180 brake calipers on the front

205 1.6 gti rear drums

Individual lines run to each corner (as per 1.9 gti set up).

No compensators.

 

Just wondering if anybody has experienced this issue before amd if they have, how have you solved it?

 

I have read about adjusting the pushrod on the MC, but would like some advice please

[welshpug 1,655]

just to add, the pedal doesn't go to the floor, and will release the brakes if you pull up on the pedal, but does not return of its own accord and keeps the pressure on the caliper.

[allanallen 528 2 Cars]

Gotta be the Master cylinder or servo fooked!

[camgti 56]

I've had a dead MC that was brand new. Replaced it and sweet now!

[Slo 283 1 Cars]

I swapped my servo for one that didn't look like an orange (rusty). It was de-rusted and painted by me and all greased up like new when i fitted it with no master cylinder, had a rag in the hole though to stop debris going in. 6 months later when i got round to fitting braided hoses i discovered the same problem went down no problem but wouldnt come back up without pulling it. After a lot of swearing and trying everything including laying upside down with my head next to the pedals inside a tiny council garage and using my phone as a torch i discovered that the four bolts that hold the servo onto the pedal bracket were loose, tightened these up and the pedal popped straight out and been fine since. Worth a check they are underneath the sponge sound deadening crap, and im not talking about the nuts round the outside of it.

[dcc 855]

Ok have got to the bottom of this today.

 

The servo does not want to allow the plunger piston assembly to move freely. We suspect the rubber seal has swolen slightly through lack of use over past 4 years. And as such the spring in the servo is near useless in its attempts to move the piston.

 

So after lots of greasing, with no major improvement, we have decided we now need a new servo.

[jord294 92]

I could be wrong here.

 

But when fitting larger m/c to std 205 servo, don't you have to wind out the rod in the servo ??

[dcc 855]

We did that as well, but still doesnt help the fact that piston doesnt move easily!

[welshpug 1,655]

update, servo was sticking badly, even with lube it didn't not spring back fully on its own, so I donated a spare unit which did spring back.

 

its BLAAAAKKK.

 

[dcc 855]

fits the engine bay perfect (but its now very muddy )

[dcc 855]

Just to finalise this and add something else, the brake issue was cured with a new servo. The original servo on the car was dead, the seals had expanded slightly, resulting in it not wanting to release.

 

An issue I have since had, the front extended flexi braided brake lines (which can be bought from Miles) had slipped through the rubber grommet on the shock absorber, and come to rest on the inside wheel rim. This had eventually rubbed its way through the brake line and gave me a soft pedal, which would creep to the floor under pressure. To solve this (after replacing the line) I had to find a way to locate the brake line, either side of the rubber grommet - I personally do not like the use of cable ties here as they can slip along the pipe.

 

Also on a side note, you NEED to ensure you fit the correct unions when using the braided lines. A union with a shoulder before the thread starts is not good enough, and you wont get more than 1 to 1 1/2 turns of thread into the flexi. I couldn't find any shoulder-less unions when I build my car initially, so I cut down a shouldered union to fit, sanding it off for a nice smooth finish. I now get 3-4 turns in the flexi. I recently found a car with the same braided lines fitted, but using the wrong union, which fell apart when I went to work on it.

 

 

You can see the thread carries along to the end of the union.