DC2 brake problem.


Ryan-EK9

Ryan-EK9

Active Member
Joined
Jul 31, 2011
Messages
445
Having a bit of trouble with my DC2 brake pedal feel. Ill start you off.

I replaced the rear calipers with new/reconditioned due to the handbrake having a million clicks and not holding the car anyway. Meanwhile I decided to paint all the calipers whilst I was taking them off.

I clamped all hoses to minimise loss of fluid before removing and fitted all calipers back. Bled the system and pedal feel was fine. Here's where the problem began. Once the engine was turned on the pedal travel was long as if air was still in the system. So I rebled the system (done this about 8 times in total) but pedal was still the same. Feels good when engine is off. Long/spongy pedal when engine is on.

I decided to replace the brake master cylinder and servo but this didn't cure the pedal and the pedal feel was exactly the same. The brakes do work. Can even do an emergency stop with little worry, but the pedal travel is just to long and isn't how it was before i replaced the calipers.

I've had it in a friends garage and he can't cure it either.

Has anyone had this problem or know of a possible solution?

Any help would be appreciated as I'm beginning to pull my hair out. :angry2:
 
I had this problem but replacing the bmc & servo did cure it for me. I later found out 1st stage seals were shot in the old servo. How much is alot of brake pedal travel is there ? Almost to the floor ?
What about the vacuum hose is on there good with the clamps, no air leaks ? Maybe another thing to look at since it uses some atmospheric pressure from the mani. Or bleed the 2 lines at the servo itself just open them little not much just to see if there maybe any air at the start of the system.
 
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You 100% sure non of the slides on all the carriers are seized, evrythings free? Thsts what id be checking after youv checked youv got a good vacume to the servo.
 
dk11290 said:
I had this problem but replacing the bmc & servo did cure it for me. I later found out 1st stage seals were shot in the old servo. How much is alot of brake pedal travel is there ? Almost to the floor ?
What about the vacuum hose is on there good with the clamps, no air leaks ? Maybe another thing to look at since it uses some atmospheric pressure from the mani. Or bleed the 2 lines at the servo itself just open them little not much just to see if there maybe any air at the start of the system.
Click to expand...

The brakes come in about an inch from the top of the pedal but goes down as stops about an inch from the bottom of the pedal. The vacuum hose seems to be intact and the one way valve is doing its job.

Ill try bleeding it from the mc itself. That's if the garage hasn't already done that. Thanks :)

Ellis said:
You 100% sure non of the slides on all the carriers are seized, evrythings free? Thsts what id be checking after youv checked youv got a good vacume to the servo.
Click to expand...

Originally, the N/S/R sliders were seized on. I got them freed up and have had the back calipers off a number of times and are still free.
 
Ryan-EK9 said:
The brakes come in about an inch from the top of the pedal but goes down as stops about an inch from the bottom of the pedal. The vacuum hose seems to be intact and the one way valve is doing its job.

Ill try bleeding it from the mc itself. That's if the garage hasn't already done that. Thanks :)



Originally, the N/S/R sliders were seized on. I got them freed up and have had the back calipers off a number of times and are still free.
Click to expand...

yeah inch at the top is not much to worry normally get 1/2" to 1" freeplay on brakes before you get any real feeling, yip thats exactly what my pedal done.. At its hardest on the brakes was about inch from the bottom. Had any luck with this man ?
 
Tyred cracking the nuts from the master cylinder and lettin the fluid run out, but no signs of air. But the brake pipe closest to the bulkhead, the fluid coming out was very 'lazy', as if the pressure was low.

After doing that, the pedal feels a little better but still no where near the feel as my EK9 pedal feels :(
 
does your DC2 have ABS mate?

if so you may find bleeding it with the engine running helps...
 
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