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Just last night I rebuilt the master cylinder on a friends saab 900. I had read up a bit on Saabnet, and there were all sorts of warnings there about pressing the pedal to the bottom as well. Maybe it's just a swedish thing...
Anyways, I had the MC apart, the seals were moderately worn, but the interior of the MC was prisitne-no marks, no scoring, no discolouration anywhere.
Thinking about the process of rust in the MC, would not all of the interior of the MC be exposed to the contaminated fluid, and not just the 'unused' lower portion of the bore? Maybe the piston could wear part of the bore larger, and pressing the pedal beyond this lip could damage the seal? Have to be in pretty bad shape to begin with and need rebuilding anyways...
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