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problem, master cyl or booster?? 

 

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 Post subject: problem, master cyl or booster??
Posted: Tue Sep 18, 2012 5:46 pm 
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hey guys
ive got a bit of an issue with my au1, did a series2 suspension upgrade with ba brakes using the au2 master cyl and booster..

now the issue is when the brakes are applied when the engine is running the pedal is really slow to return, sometimes it stays down, the brakes work great except for this issue..
now my first thought was spring in the master cyl is week or broken, but when i start the engine sometimes the pedal is pulled down :? ..
even when driving if i apply light braking then accelerate the vacuum from the engine applies the brakes further...
thoughts??????????
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 Post subject: Re: problem, master cyl or booster??
Posted: Tue Sep 18, 2012 5:49 pm 
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Definately something a miss in the master cylinder I reckon.

 

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 Post subject: Re: problem, master cyl or booster??
Posted: Tue Sep 18, 2012 6:45 pm 
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 Post subject: Re: problem, master cyl or booster??
Posted: Tue Sep 18, 2012 7:15 pm 
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So the pedal operates as normal with no vacuum ??

Couldn't really tell that from that video - either that's you huffing and chuffing, or does that booster sound noisy ??

 

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 Post subject: Re: problem, master cyl or booster??
Posted: Tue Sep 18, 2012 7:29 pm 
Getting Side Ways
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From the video it looks like the booster is stuffed.
It should be making the whoosh noise as bad as it is unless its the video making it louder then it is.

 

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 Post subject: Re: problem, master cyl or booster??
Posted: Tue Sep 18, 2012 7:39 pm 
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snap0964 wrote:
So the pedal operates as normal with no vacuum ??

Couldn't really tell that from that video - either that's you huffing and chuffing, or does that booster sound noisy ??


the pedal operates fine with no vacuum but is still a bit slow to return.
and the noise is from the booster not me ...lol

EVL098 wrote:
From the video it looks like the booster is stuffed.
It should be making the whoosh noise as bad as it is unless its the video making it louder then it is.


the sound is probably louder than normal as the phone was pretty close to the pedal...
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 Post subject: Re: problem, master cyl or booster??
Posted: Tue Sep 18, 2012 8:08 pm 
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I'm tending toward the booster - best unplug the ABS unit to rule it out too.

The base of the plug slides out like a tray, so it unlocks the tabs, then you can pull the plug off.
I think the AUI and AUII Ghia 4 channel ABS units might have different calibrations, but I'm pretty sure the unit part nos are the same, and so are the front and rear tone wheels.

Note the Mast cyl differences I mentioned in post1352901.html#p1352901

 

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 Post subject: Re: problem, master cyl or booster??
Posted: Wed Sep 19, 2012 4:45 pm 
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problem has been found, and its a strange one ..

it would seem the firewall angle is slightly different from au1 to au2 ?
the rod from the booster to the brake pedal was binding because of the angle of the rod being to much. (dont know if anyone has come across this before)?
when i mounted the au2 booster to the au1 the nose of the master cyl was 15-20mm lower compared to when fitted to the au2.. meaning the rod going to the pedal was now 15-20mm high then normal, i was kind of wondering why it was so difficult to put the rod on the pedal pin..
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 Post subject: Re: problem, master cyl or booster??
Posted: Thu Sep 20, 2012 12:16 pm 
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That IS an odd one! Who would have guessed a change in firewall between AU1 and 2. How are you going to fix it? Can you go back to the AU1 booster? Modify the firewall where the rod interferes with it? Or somehow adjust the AU2 booster angle (spacers or something)? Thanks.

 

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 Post subject: Re: problem, master cyl or booster??
Posted: Thu Sep 20, 2012 12:30 pm 
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TROYMAN wrote:
problem has been found, and its a strange one ..

it would seem the firewall angle is slightly different from au1 to au2 ?
the rod from the booster to the brake pedal was binding because of the angle of the rod being to much. (dont know if anyone has come across this before)?
when i mounted the au2 booster to the au1 the nose of the master cyl was 15-20mm lower compared to when fitted to the au2.. meaning the rod going to the pedal was now 15-20mm high then normal, i was kind of wondering why it was so difficult to put the rod on the pedal pin..

The AU1 uses the same booster as the E series, whereas the AU2 onwards is different. I found this out on the forum the other week when replacing the booster in the wagon.
If I had read your thread properly the 1st time around I could have told you what the problem was. :oops:

 

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 Post subject: Re: problem, master cyl or booster??
Posted: Thu Sep 20, 2012 1:25 pm 
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the main reason for the whole swap was to run bf brakes, at the moment ive fitted the au1 booster with the au 2 master cyl and bf calipers and rotors...
i knew the series 1 had the stupid plastic ef/el booster, but afaik the firewall was the same except for drilling the holes..
i know of one or two people who have fitted the au2 booster to their ef's might have to ask if they have had this issue.
the turbo will be going on the au soon and i definatly dont want the booster melting..lol

so im looking at making a spacer plate to go under the booster to lift it up, there is a 15-20mm difference but i should away with spacing it up about 6mm..
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 Post subject: Re: problem, master cyl or booster??
Posted: Thu Sep 20, 2012 4:03 pm 
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TROYMAN wrote:
i know of one or two people who have fitted the au2 booster to their ef's might have to ask if they have had this issue.
Corey's setup comes to mind (as you know).

 

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 Post subject: Re: problem, master cyl or booster??
Posted: Thu Sep 20, 2012 4:48 pm 
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anyway i have now fixed and fitted the au2 booster :D .
i made a wedge plate that is 4mm at the bottom and .5mm at the top and the booster rod lines up perfect.. no more pedal sticking or strange noises,,, :D
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 Post subject: Re: problem, master cyl or booster??
Posted: Mon Oct 29, 2012 3:49 pm 
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to update this.
after doing some investigating and comparing the 2 firewalls, i have found the difference..
the difference is where the firewall joins upper cowling?.
in au2 the lip join is higher up allowing the booster to sit flush where au1 is angled lower..
the red line in the pic is where the au2 lip is joined and you can see in the pic where the series 1 lip joins..i have persuaded it with a few belts of a hammer.. :lol:

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 Post subject: Re: problem, master cyl or booster??
Posted: Wed Oct 31, 2012 11:06 am 
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i wonder if i will encounter the same problem when i install my AU2 booster/MC setup in my EF???
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