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Brake Booster Malfunction?? 900 1994

posted by  Townshend Act on  Wed Nov 19 00:47 CST 2014
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last visit: Tue Oct 7 22:44 CST 2014
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Hi all. I've just completed an overhaul of my Girling / ATE / Bosch ABS brake system to include master cylinder, booster, brake calipers, hoses, hardware, pads and rotors. The entire system was flushed and is immaculately clean and sealed.

My problem is an EXTREMELY sensitive brake pedal. When depressed, it engages excessively hard such as I'm jamming on the brakes. The system seems "over-boosted" and I wonder if I received a defective booster (rebuilt) or there is an adjustment I missed.

I have altered the pushrod adjustment to different settings and while changing the pedal height and engagement, when engaged the system still brakes excessively hard.

Any thoughts or ideas folks? Bad booster? Bad caliper(s)?

Thanks.

John






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