Quote Originally Posted by GTS View Post

If the new master cylinder, which is arse about face to the old one, is off a later model then my question would be "is the pushrod between the booster and master cylinder the same length????"

I have come across this before where as little a 3mm makes a huge difference. Can anyone confirm one way or the other?
I know, I'm replying to my own question....but the scary part is that my suspicion was right....for a change.


After I got the air out of the l/h caliper it turned out it didn't make any significant difference.

Today, after sitting in my, now well worn, pondering chair last night killing off some excess brain cells with my favorite brew I made a 3mm spacer to go over the end of the push rod out of the booster. The result was instant...full, hard pedal. It still needs a little tweak but I had to start somewhere.....I reckon a 2.5mm spacer will be on the money so I'll trim this one down in the morning.

Prior to this, after clamping off all 3 hoses and getting full pedal, all I had to do was remove either 1 of the front 2 caliper clamps and the pedal crept to the floor. I knew it couldn't be the calipers full of air anymore so I started looking at the master cylinder. I figured that the pedal was creeping because the seal hadn't gone past the little vent return hole and was bleeding internally....almost as much as I was after spending 2 weeks trying to find the problem. The pedal sunk to the floor as if I had a slightly open bleeder nipple...there was a bit of pressure there but it still went to the floor.

So theres yet another solution to a brake problem....although I guess it'll only ever come up when you make 1 van out of 3 then start using new and old parts. BTW, the only old part of the braking system is the booster and the pedal. Lesson learned.