Thread: D2 Brake master cylinder repair kits

Ignore all my comments - I thought you were talking about the clutch one - clearly i cant read! sorry.

Geez, I wish the dealer had told me to fix the master cylinder myself!

I dropped the D2 off to the dealers designated mechanic at 8.00am Tuesday and I'm sitting here Saturday morning wondering when I'll have it parked in the drive next!!

The D2 sat in the workshop all Tuesday waiting for a replacement master cylinder which eventually turned up Wednesday afternoon.

After fitting the master cylinder and bleeding the brakes the car was test driven and on the way back to the workshop the brake pedal went hard. This was diagnosed as a fault brake booster. A replacement booster was ordered on Thursday and mechanics promised it would be there first thing Friday morning.

I rang them at 12.30pm only to be told "The booster hasn't turned up yet. I was going to call and find out where it was, I guess I should do that now..." FFS!!

Rang up at 4.30pm and was told they had just finished fitting, and to come down and pick up the D2. Got halfway there on the tram and the mobile went... they had problems - the brake pedal was still hard and they had no idea what the problem was so were pulling the booster and master cylinder apart again.

Anyway I'm so over this debacle I'm going to drop down and talk to them on Monday morning to see what the situation is and want to have an idea of what might be possible fixes/things they haven't tried.

I've done a bit of reading of various forum posts and have a number of potential causes for the hard pedal:

• air in abs modulator - requires modulator bleed
• leaking vacuum pump to brake servo hose - remove hose from servo and block end with motor running to check for leaks
• missing o-ring between master cylinder and brake servo - I've seen one post mention that the o-ring was missing from replacement master cylinder and transferring the old o-ring solved the problem.

The brakes were fine apart from a slow leak from the brake fluid reservoir o-rings prior to the D2 being "fixed", so I'd guess the fault is direct consequence of replacing master cylinder.

Any suggestions?

cheers
Paul