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1bam777 Regular Location: Perth WA Registered: May 2002	Re: brake problem... i think i've tried everything... Sat, 06 July 2002 12:06 Barbel, 2 things that MIGHT have gone wrong. I had this similar problem when I had my master cylinder o/hauled. 1. The actuator rod behind the master cylinder, the one that actually pushes on the mater cylinder, might not have enough clearance. I had to linish/grind mine down about 2-3mm for adequate clearance. Make sure that the rod doesn't 'push' into the master cylinder when you bolt it back in. Before this modification, my brakes would start to 'grab', with an extremely hard pedal. And the only way of 'relieving' this brake'grab' was to release the pressure in the master. Please read point 2 before checking... 2. The removal of the actuator rod in the vacuum booster can cause a few problems. If the rod was removed without securing the reaction disc, then this 'disc' could fall out of place, causing a similar 'grabbing' problem, but the brakes would not lock on. Pedal would sometimes feel spongy. Unfortunately, the only fix for this would be to send it out to a very good brake specialist, and have him fish around the inside for the disc, and to put it back in its proper spot. Keep in mind that most brake ppl will tell you that a new booster will be needed, and this is not needed if the booster is not leaking. If the actuator rod was removed or disturbed when the master cylinder was out, then this might also cause part of the problem. I had this happen to me about 6 months ago, and I was pulling my hair out over the whole thing..!! The reason that I can think of for the pedal getting harder as you drive along is that the booster might be activating the brakes. If the actuator rod is too long (without adequate clearance), the vacuum in the booster will be pushing the rod into the master, and that will cause a harder pedal. Take a look at your master cylinder, and it should tell you the size of the internal bore. I know that the local AE86s and the import AE86s have a slightly different bore diameter. As Dorikiin would have said, the spongy pedal is because of a mismatch of calipers and master cylinder bore size... Email me if you have any questions.... Hope this helps! And sorry about the longish post!! Cheers! Zack. [Report message to a moderator]

	Subject	Poster	Date
	brake problem... i think i've tried everything...	barbel	Tue, 02 July 2002 08:37
	Re: brake problem... i think i've tried everything...	dorikin	Tue, 02 July 2002 11:36
	Re: brake problem... i think i've tried everything...	barbel	Tue, 02 July 2002 11:50
	Re: brake problem... i think i've tried everything...	dorikin	Tue, 02 July 2002 12:17
	Re: brake problem... i think i've tried everything...	barbel	Tue, 02 July 2002 12:48
	Re: brake problem... i think i've tried everything...	dorikin	Tue, 02 July 2002 12:52
	Re: brake problem... i think i've tried everything...	Manny	Tue, 02 July 2002 13:15
	Re: brake problem... i think i've tried everything...	celica_freak	Tue, 02 July 2002 15:05
	Re: brake problem... i think i've tried everything...	barbel	Tue, 02 July 2002 22:16
	Re: brake problem... i think i've tried everything...	barbel	Thu, 04 July 2002 22:26
	Re: brake problem... i think i've tried everything...	1bam777	Sat, 06 July 2002 12:06

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