Normski 1 Posted May 16, 2007 Just thought I'd document the problem (and solution ) I had when fitting a 406 23.6mm master cylinder (bought from Brakeparts.co.uk) to my 205 fitted with 306 GTi-6 front brakes. The problem was that after fitting the new M/C I was disappointed to find that the pedal travel was still too long, negating the whole point of fitting it. My first thought was that I'd been supplied the wrong part (i.e. a std 1.9 20mm one) because I didn't feel any difference and there wasn't any diameter markings on the M/C. So to rule that out I contacted Brakeparts technical dept and told them my problem, they where very helpful and agreed for me to send it back for them to measure. Which they did very quickly sending me photos in an e-mail. Turns out it was the correct M/C, so there was some other problem and they gave me some things to check. The most likely one being the clearance between the M/C and the servo push rod. I didn't realise the precision needed for this measurement which is 0.1mm !! According to the Haynes the distance from the servo flange to the tip of the servo push rod should be between 22.2mm and 22.4mm, I measured mine to be 22.7mm. So I adjusted it to the optimum 22.2mm. I didn't have much faith that this change of 0.5mm would do much but I was wrong. The pedal is far better now, how it should be. So check that when you are fitting yours and save yourself a couple of litres of brake fluid. Share this post Link to post Share on other sites
petert 587 Posted May 16, 2007 It's also very easy to get that clearance wrong the other way, meaning that every time you put your brakes on, they never release. Until eventually you come to complete stop, stuck in the middle of nowhere, unable to move your car! Luckily I had an 11mm spanner and was able to crack a brake line! Share this post Link to post Share on other sites
