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1993 RHD, UK 2 litre LPT CDE with mark IV ABS, 148k miles. Help required with poor braking problem.
The brakes are poor, requiring a lot of effort to stop the car quickly, although not as much as if the servo (brake booster) was not working. The brake pedal goes down easily about a third of travel but then requires a lot of effort to get the car to stop and has a springy feel to it.
Without the engine on, once the vacuum is expelled from the servo the pedal is firm but still springy with about 1 inch of travel. The master cylinder/ABS pump/servo unit can be seen to move slightly to the side when the pedal is pushed hard yet the retaining nuts and the servo nuts are tight. With the engine running, when the pedal is pushed, air can be heard going into the servo and if it is slighlty released air again can be heard going in. The slight movement does not seem normal and I have looked under the dash at the pedal and servo end to see if there is an obvious fault such as loose nuts/damaged bush/split in floor but none noticed although a lot of the floor is covered by soundproofing. The ABS light goes out after a few seconds when starting the car.
Over the last year have replaced the master cylinder/ABS unit with a lower mileage unit but problems same. Replaced brake hoses with teflon/steel braided ones - found both front hoses had ballooned where they go through the struts and teflon set was cheaper than rubber - brake pedal then a lot firmer. Replaced all brake discs (rotors) and pads - initially used Textar pads but are too hard and groove the discs so have replaced front with Saab but still have rear to do. Replaced sections of badly corroded brake line around back axle. Replaced both rear calipers with reconditioned since had started clicking and one had stopped self adjusting. Rear brakes adjusted to third of a turn using 4mm allen key. Cleaned out inside of front calipers since one was partly seized but did not replace rubber seals since about £20 from Saab per caliper and appeared ok. Bled brakes many times using various methods (running pump/opening ABS valves as Saab manual, pressure bleeding, running pump to bleed rear - as notes on this board).
I am now at a loss as to what I should try next. All the work done so far has been necessary apart from possibly the replacement master cylinder/ABS pump. I have a lower mileage servo unit which I could try but first would appreciate any ideas. If anyone could see if their ABS unit moves slightly and the servo lets in air when pushing down and also when releasing the pedal on a RHD car that would be appreciated since it would suggest this is normal. Any other thoughts would be appreciated.
posted by 53.122.20...
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