Brake Problem on AE101

[FLESHAXXE]

I have a 93 silver top 20v levin(super strut) and I have recently purchased front and rear caliper kit and had them installed...I have even installed a new master cylinder kit as well..the problem I have is that I have not been able to get the brakes hard again...I have started bleeding the brakes from the master cylinder first...then the left rear - right rear-left front-right front and still no brakes...I have also bleed the ABS as well and still no break...the pedal is getting hard while pumping the brakes but after you take your foot off the pedal for a few seconds and mash the break again it goes to the floor...it seems like the system is not holding ..before the system was "overhauled"...the brakes were holding really well....

[tsoob]

split line?

is the master second hand or brand new?

[Bazda]

Front left is connected with right rear.
Unless your not bleeding it properly..

[Dell'Orto]

Dont use one of those one man brake bleeders! I had endless issues doing my AE101 with a one man bleeder. Did it properly and the brakes were perfect.
Does sound like theres still air in the lines.

[FLESHAXXE]

Have taken the old master cylinder out and replaced it and the same thing is happening all over again....

[strx7]

if your fluid level isn't going down mysteriously, you have air in the system somewhere

[rollaholic]

you bleeding the master in a vice first?

[FLESHAXXE]

I was told to unplug the ABS then bleed the system...will try this afternoon and see what happens...

[FLESHAXXE]

Still at square one guys....

[allencr]

...recently purchased front and rear caliper kit and had them installed... new master cylinder kit...the pedal is getting hard while pumping the brakes

Pumping up means there's air, the 'installed' means that there may be A LOT of things that aren't solid & mating together well, the 'kit' means that the MC was R&R by whatever.

I don't want to guess at which of the 3 or combination is your problem/s.
I would suggest that the 'installed' look at it & fix it.
Get the air out, look at all 4 when its being pumped to see if there's more the about 1mm movement.
Good luck.

[FLESHAXXE]

This thing is driving me crazy guys....I have tried all sorts of things...I will give it a break until weekend when I can really put all my energy into it again...I have checked for leaks at each caliper and elsewhere and have found none....

[touge_ae101]

this may seem like a silly suggestion but how long did you bleed the brakes for?if you have the whole system empty (master cylinder as well) to start with, sometimes it can take a hell of a long time to push the fluid all the way to the rear brakes. and also a possibility of having air in the line if some fluid has settled at the lowest point when everything was apart.

eliminate the obvious first, then look for a tricky solution.

[85AW20v]

You can also apply some air pressure to the system. Nothing major - sealing around the m/c cap somehow and blowing down a piece of hose would probably do it - with a bleed screw or two open.

Another thing to try is loosening the brake lines where they screw into the m/c and then applying the air pressure with the pedal at various heights from the floor. If you get fluid out of both of them, tighten and move on to the next closest joint and see if you can get fluid out of that with no air. If you can, then start the bleed process again from the back.

[allencr]

I have checked for leaks at each caliper and elsewhere and have found none....

Why does almost everyone write 'checked for leaks'???? If it was that obvious & simple they wouldn't be posting or if they did post, people wouldn't even bother to reply with a 'then fix the $&#$% leak!'

We know a fluid is not compressible, neither is a cast iron disk or the pad that the fluid squeezes. The hydraulic hose expands a bit and the MC & caliper seals give a bit when pushed between the piston and the bore, so there is very little in the system that has any give that would make the pedal anything less then 'rock solid' in theory. In practice everything but the fluid ha a bit of give.
You have air in the system that hasn't been bleed out, AND/OR an MC that is bad/put together wrong that is letting in air, AND/OR space/compliance/slack between the caliper & disk from a poor install.
Good luck.

[FLESHAXXE]

Thanks guys will try what you have suggested this weekend and let you know...THANKS...

[sark.inc]

you bleeding the master in a vice first?

YOU DID DO THIS RIGHT?

[FLESHAXXE]

I have finally gotten the brakes fixed...I took it to the mechanic and we noticed that the front calipers were all mixed up...the right was for the left and the left was for the right...the bleeding niples were facing down instead of facing up...somehow it carried an air pocket in both because when changed around they came back hard easily....thanks guys for your help...

[matt dunn]

.the bleeding niples were facing down instead of facing up..

um, would you have noticed that when you bled it?

[allencr]

um, would you have noticed that when you bled it?

You just don't think of it if you've gotten a basket case or the hose connection is almost in the same position when you put it together. It's the ones where the hose doesn't seem to fit any more, too short, too much slack, too tight a bend that seem like they've gone out of there way to get them to fit when they swap them that surprises me.