I was the author of "We got nowhere this weekend" thread. We had tried everything, but to no avail. Finally, we determined the pistons within the MC were not moving back and forth consistently, so fluid was not being built up properly within the MC. The MC had been rebuilt and re-sleeved, and we had all new components like the slave cylinder. Here is what I think happened:
- We were using a house brand of Advance Auto Parts DOT 5 brake fluid. I am convinced this was affecting the rubber seals within the system, causing them to swell and impeding the travel of the pistons.
Why? How?
Before you begin doubting me, let me explain further:
- We purchased an EZ Bleed system from Advanced Auto. It contained two plastic reservoir bottles that attached to the system and were used to allow the fluid to pass through. After several failed attempts at bleeding the system, we had brake fluid all over these things. We were told that if the EZ Bleed did not work that we could return them, so I began to clean these things up. Each time I disconnected the reservoirs from their tools the rubber seals around the necks of the reserviors popped off. When we tried to reinstall these seals they wouldn't fit. THEY SWELLED UP AND WOULD NOT FIT IN THE VERY GROOVES IN WHICH THEY FIRST CAME. In other words, contact with the DOT 5 caused these seals to swell to the point they were no longer any good.
We took the MC to a local, high end resto shop which had extensive experience with all types of British cars. They eventually determined that the pistons within the MC were not traveling freely. They ordered a simple rebuild kit from Moss, flushed the MC completely, rebuilt it (changed out the rubber parts), and bench bled it with DOT 3/4. We cleaned out the hydraulic system the best we could, re-installed it, and it works perfectly.
I believe, at the least, the DOT 5 was affecting the rubber parts (BTW: We replaced the slave after having the MC rebuilt because the seals in that were also affected). It could be that the house brand AA DOT 5 was misformulated, but the resto shop told me they had bad experiences using DOT 5 in their British cars and that they use only DOT 3/4.
That's my story and I'm sticking to it.
MXP