I've just finally got round to getting my Pug on the brink on being back on the road. I've replaced the brake pipes and hoses, and cleaned up the calipers, got new discs and pads all round. The servo and master cylinder are the same, but cleaned up (gave the servo a lick of paint too). Before the refurb, the brakes were mostly fine with just the rear right being a bit weak (enough to fail the MOT), but with good feel and stopping power.
However, I tried them out for the first time this evening and the brake pedal had a lot of travel before the brakes engaged. Once they did engage they seemed to work well, which suggests the calipers are moving OK.
I've bled the system a few weeks ago and did it again today to make sure there was no air in the system, but that didn't improve things.
Any suggests on how I can pin down the cause of this pedal travel?
BTW, it's 205 GTi 1.9 with the standard non-ABS brakes.