Very long brake pedal travel

[Craigwilson]

Okay I have a 91 8v GTI, a few years ago I fitted the girling 60 callipers with the 280mm discs a new 23mm master cylinder and all flexi hoses are good ridge braided and I just fitted and new brake load sensing valve. But since i fitted the big brakes my brake pedal has had a huge amount of travel It has about 3 inches of slack before there's any pressure but when you take up the slack it is giving gentle brakes and when you push on the pressure after the slack the brakes are amazing. Does anyone know how to sort out the long pedal travel its begging to get annoying, thanks.

[molegti]

You need to fit a larger master cylinder. 22mm from a 16v.

[Craigwilson]

I have a 23mm master cylinder fitted

[X4MGS]

When did you last change the fluid?


Are you also sure the MC is not leaking & needs replacing??

[Craigwilson]

Bled the whole system today, all new brake pipes, I'm very sure the MC isn't leaking because the brake have been like that since the MC was new those brakes have just always been like that but the MOT tester says it has to be fixed.

[X4MGS]

Did you bleed enough to change the whole system??


If yes,  then the MC need replacing as it bleeding internally.


It wont leak externally as such but the rubber seals inside are letting air into the system...

[Craigwilson]

Yeah I'm sure I bled it right through, would the seals leaking internally still give me the amazing brakes tho because once you push it they really are

[X4MGS]

Yes at times and at others NOTHING.... Same thing happened with my lads 1.6 driver...


I drove it... brakes perfect... he drove it back home brakes failed...


all down to the MC so we fitted a new one.. all fine all the time..

[Craigwilson]

Well I'm not at the stage of no brakes as long as you take up the travel and then press into the pressure the brakes are good every time and its been like that over 2 years.

[X4MGS]

I'm no mechanic..


BUT I'll put £10.00 bet on that the issue is with the MC....


TBH Stuff like brakes are not worth the chance of killing someone, so get them checked out by someone who knows MK2's and what they are doing....


Just not worth the risk..