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Braking System
Posted by Alain Delbarre (more from Alain Delbarre) on Tue, 7 Mar 2000 11:03:09
In Reply to: , Kok Chen, Sat, 17 Dec 1988 12:00:00 

The braking system of my SAAB 900I 8V 1986 (handbrake on front wheels, no
ABS) has been recently repaired : new master cylinder, rotors, seals and
caps in wheel cylinders, front pads and clean calipers. However, I'm not
happy. When driving, I can stop the car in a normal way (I did'nt try
emergency braking) but the travel of the brake pedal is much longer than
before. With the car stopped motor running, the pedal slowly plunges and
stops approximatively 2cm to the floor. Motor off, the travel of the pedal
can be strongly reduced by pumping the pedal several times. On cranking,
the pedal plunges two or three centimeters due to the action (I guess) of
the servo unit. The handbrake is no longer operating but it's not unusual
for me. Fixing the handbrake mechanism on the front wheels is apparently
tricky. Since 1986, I probably spent half of my time without handbrake
system.

The hydraulic fluid (Dot 3 or 4) has been renewed. There is no fluid
leakage at the wheel cylinders and the level does not change in the master
cylinder reservoir. The system has been bleeded several times and is
apparently free of bubble or foam.

In fact, the pedal is not really spungy, the travel is just too long.
Sounds like a pressure problem. I can't imagine where the problem is coming
from and which part is defective

-The servo unit ? I suppose the pedal should be hard all the time -The
master cylinder ?  The new cylinder (from the local SAAB dealer) is
probably not completely roasted. If so, I suppose the pedal should not
harden and stop plunging before coming into contact with the floor.
However, the Haynes manual says that the master cylinder operates two
almost independent circuits. A dual assembly cylinder/piston causes brake
fluid to flow through the brake lines in both circuits. In the event of one
circuit failing,  the full pedal effort is transferred to the working
circuit but the travel of the pedal is increased. How could I check a
possible failure of one circuit ? -The wheel cylinders, calipers, pads ?
should the increased travel of the pedal be provoked by the excessive
motion of some working part of the braking system within the wheels ?

Some idea ? Many thanks for your help

Alain
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