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Master cylinder/brake booster contamination question 900

My master cyclinder has been slowly on it's way out while waiting for me to get around to replacing it. No fatal problems other than pedal travel is a bit too far (never to the floor) and braking is mushy. The other day I had to do a panic stop and really put my foot down letting the ABS do its thing. Pedal travel was as usual. Now the brake fluid level appears to have suddenly dropped. No visible signs of leakage so I have to assume the fluid was forced back into the booster.

It would seem I've got to get that fluid out of the booster rather soon before the diaphragm gets affected or is it too late? Anyone got any thoughts/tips on dealing with a contaminated booster? Soapy water, rinse and throughly drying it out would be my thoughts. I'm not in the mood to get another booster even a used one (the local yards know their prices and charge accordingly).
--
Dave - '95 945 Turbo w/ABS








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    Master cylinder/brake booster contamination question 900

    I would verify the booster theory by uncoupling the MC and moving it forward a bit so you can look for what you suspect. If it looks dry, you'll have to look elsewhere. I've not actually done this on a 900, but have moved 200 MCs several times. Should be a 10-minute job.

    I had a slowly dropping MC level and sinking pedal on a 200, that finally turned out to be a leaking piston on a front (4 piston) caliper. Most of the leaking fluid was being trapped inside the rubber boot, so there was practically no evidence (up to that point).
    --
    Bruce Young
    '93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.








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      Master cylinder/brake booster contamination question 900

      Thanks for making more aware of that possibility, Bruce. Turns out you were absolutely on the right track. The master cylinder connection at the booster and inside the bottom of the booster seemed dry. I've now pulled every caliper to carefully checked for fluid behind the boots. During my heavy footed panic stop I managed to push a load of fluid past the seal of one front brake. There was a fairly large amount of fluid suddenly unaccounted for, so when I originally inspected the calipers and everything was dry I just assumed it was more likely the worn master cylinder dumping it back into the booster. My 900 uses a single piston (clamshell style) front brake and the dust boot is very well sealed to the piston. Unless the piston is fully retracted a fairly large volume can hide behind the boot. I drained and cleaned the piston and yesterday put in a new master cylinder carefully attempting to do it without a full bleed as I had just pressure bled the entire system not that long ago. I'm still not happy with the brake feel so I'm going to re-bleed and if that doesn't satisfy me then the booster goes back on my suspect list as I can still hear occasional hissing when I take my foot off the pedal. My wife also has a 940, higher mileage like mine and with an identical brake system. The brakes are as hard as a rock and I won't be satisfied until mine is as good.
      --
      Dave -not to be confused with a real expert








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      Master cylinder/brake booster contamination question 900

      Thanks, I'll certainly verify the booster leak as you suggest before making the final diagnosis. I came to the booster theory reluctantly and only by process of elimination knowing that the master cylinder was already due for replacement and I'd externally inspected fairly carefully around the master cylinder, ABS unit, brake line connections, hoses and calipers. I'm mostly interested in what my options are and how high on my priority list this project needs to be if my fears are correct.
      --
      Dave








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        Master cylinder/brake booster contamination question 900

        It might be that the fluid was actually sucked into the engine through the vacuum connection to the booster and burned.








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          Master cylinder/brake booster contamination question 900

          I only figured it would go that way if the booster really filled up. What I'm planning to do at the moment is pull the vacuum connection and drop a string wick down into the booster to see if there's any residual brake fluid in the bottom. Thanks for your input.
          --
          Dave -not to be confused with a real expert







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