Just replaced the master cylinder on Rover 825 Coupe 1996. Replacement cylinder came from car with good brake pedal. Have bled system using miti-vac vacuum system, and by conventional pedal pumping. System has pressure and pedal feel is better than previous master cylinder (which had failed seals) but pedal is still poor with too much travel. Still feels like air in the system. There are no leaks, clamping the flexis off makes little difference, there is no pad knock-off due to wheel bearing play. Has anyone had this problem? Any special method needed bleeding the brakes?

92472, November 2006

9/10 times this is caused by a pad not travelling freely in a caliper. This causes the other pad to strain the disk onto the stationary pad and the extra travel causes excess pedal travel. Clamping the flexi may help identify this, but in my experiance clamping rarely works as fluid can still get through modern pipe designs.

alex, March 2007