Any Ideas?????

[FletchCossie]

Right, had a brake problem on me S2 RS Turbo since I accidently pulled a pipe out of the master cylinder when fitting a gearbox.

What's Happening:
The brakes seem to work when the pedal is near the bottom of travel. Before the brakes start working there is a clicking noise from the front drivers caliper, which I found to be the caliper juddering (Moving top and bottom) as if the ABS was working. If you stamp the brakes on they work after a few seconds and stop the car...

We Have Replaced:
All Brake Lines (Removing ABS) including fitting of braided lines all round
Reservoir and cap
Servo
Drivers caliper
Bled the system through 15 times in total and final time was tonight, no air appears to be in system.
(All parts donated from S1 RS Turbo)

Yet the problem still continues. I took it to a brake specialist locally when the problem started and they said "Everything feels fine".

Anyone got any suggestions as to what could be causing the problem or any ideas how to solve it??

[Lee H]

Check the bulk head where the pedal and the mater cylinder mount I have seen these crack giving you less pedal pressure.
The self adjusters in the rear drums can sieze meaning you have push the pedal more before the brakes work.
Warped front disc which pushes the caliper back meaning you have to push the pedal more before pads touch the disc.
Front disc not fitted flush ie rust or old mounting screw won't let the disc sit flush.

Lee