[ausgeflippt951]

Ok, I need to bounce some thoughts off you smarter-than-I gurus:

The brakes on my car ('86 951) have been oddly soft for years (since I bought it, six years ago). They have a long pedal travel that does not get impacted by pad thickness, fluid newness, etc. With the car running, it's about twice (or more) the travel it should be.

I've been tracking with my car for the entire time and while I have been religious about servicing my brakes, I can't get this damn softness to go away. I like a rock-solid brake pedal, and this most certainly is not.


I'm thinking it's my Booster, purely through process of elimination: it's original and is the only thing I haven't replaced. That said, the boosters on these cars hardly ever fail, and when they do it's a leakage that causes a slow leak of pressure when the brakes are applied. In my case, if I hold my foot on the brake, once pressure is built it doesn't continue to drop. It just takes a lot of pedal travel to pressurize.


1) Master cylinder is new
2) Brake pads are new
3) Fluid is new, and the issue persists regardless of the brand. Currently have EXP600.
4) Calipers have been replaced with New-Used units, and I felt no change in pedal application. Indicates calipers likely aren't the issue.
5) New stainless steel lines, and the hard lines are in good shape with no kinks as far as I can see.
6) The booster check valve seems to be working: I can get flow in one direction but not the other. They're cheap so I have a new one on order anyway.





Thoughts? Here's something else I've been considering but wary of: perhaps the brake pedal clevis needs to be adjusted? The pedal travel with the car off (non-boosted) is pretty short, so I'm hesitant to fool with the brake pushrod.


Thanks in advance!