Ok, folks, so for those who didn't witness my crying in the forums about my brakes, I will bring you up to speed........   

 

 

 

Okay, now that you are up to speed, I blasted everything apart and was finally able to install my performance brake pivot from I.E. The existing pivot was a bit rusty but ultimately functional. The new one feels better, but I haven't tried putting any fluid in the system. 

 

I was convinced that shims were required behind the push rod that goes into the M/C. So I got the tiny little shims (a bag of over 100) and had at it. While there, I sandblasted ( glass bead) everything and gave it a good coat of my favourite paint, Steelit. I assembled and installed it.

 

One note on assembly with the performance pivot.    There is a support bracket that bolts to the fender, but you will need to remove it, as you can't align the bracket to the bottom bolts of the brake booster, so slip the central pivot bolt over the bracket.   You must do this because you can't remove the bolt holding in the pivot; you need to drop it over the slotted bracket, so you can't slide it back to clear the fender-mounted bracket. 

 

I know this is a mouthful, and to be honest, I should have removed the two bolts on the fender bracket and the four at the firewall, loosened the main pivot bracket, and pulled it all out as one unit.   Live and learn

 

Now that I have the main bracket installed and the pivot bolt tightened (not too tight, or the performance pivot won't roll), I can proceed to the original task of shimming out the push rod, eliminating space between the rod's tip and the MC. 

 

So I stacked 6, then pushed the M/C flush; nope.. too many... so I took another one-off, nope, still pushing off.... so that continues until I have one 0.5 mm shim.    So, long story short, there isn't a problem with the shimming of the actuator rod.  F&%K !!

 

I got my old M/C and tried it, but I still felt the same. Okay, so plan B is to take the new M/C apart.

 

I found the little washer floating around inside the spring. It is essentially doing nothing. The second picture shows how I think it should go.  

 

Some small holes in the piston look like they are there to let fluid pass through.  If the spring is pushing on the rubber seal, I don't think it will allow the fluid to flow through.  I will need to look at this more, but loose parts inside the M/C seem like a red flag. 

 

Any thoughts would be greatly appreciated. 

 

Regards

 

This is what I found when I popped out the piston.  

 

 

I think that It should look like this. 

 

 

Here are the holes. 

 

 

 

This is how the small washer sits on the shoulder of the piston. 

 

 

Here is the entire internal assembly.

 

 

Bore measurements look ok. 

 

 

Before Pictures. 

 

After pictures