Brakes problem

[valour]

This seems to be a new one for all the mechanics and brake specialists, so I am hoping someone here may have heard of this before. My brake pedal has, over a period of two years slowly been getting lower and lower when it returns. Now it is several centimeters lower than the clutch pedal ( Towards the floor like it is being put on ). It is so low, it won't even turn the brake light off any more. I have had the master cylinder replaced, as well as the brake switch. I have the rod from he brake pedal to the master cylinder wound out until there is nearly no thread left. The rod itself seems to be normal length and not overly worn. The brakes are up tight and seem to be working as they always have. It just seems that there is something in he system stopping the master cylinder from returning all the way and pushing the brake pedal back to the original position. Any ideas on where to look would be greatly appreciated, as it is a couple of months out of rego and needs to done soon.
Thanks.

[FCRB26]

have you checked all 4 brakes are actually working as their might be a blockage in your flexible lines.
do all 4 corners bleed properly really fast not a dribble?

i have had toruble bleeding a clutch before similar circumstances i ended up using a suction style bleed system and it got the air pocket out and fixed it.??

sounds like fun anyway.

[fossil]

I had this happen all of a sudden when the brake return spring fell off (the top of the pedal). Maybe your spring is fatiged and needs replacing?

[mcl1959]

I would check all 3 flexible lines - sounds to me that one or all are restricting flow. If one is a bit sus, I would replace all 3. The other cause could be gummed up valve in the end of the master cylinder, but this should be OK since the cylinder has been rebuilt.
Check the return spring is in place as stated and check that the pedal has not gone dry in its bush.

Ken

[valour]

Fossil and Ken, I don't appear to have a return spring attached to the pedal. I have one on the clutch, but everyone has been telling me that there isn't one on the brake pedal and it returns via hydraulic pressure.
Thanks for your time.
Bruce.

[Stewy]

Hi, Spring-Brake Pedal Return    FE/FC   part # 7411850 not that it helps much but it is not the same as the clutch pedal return spring which is FE/FC/FB  part # 7410145

Cheers Stewy.

[jasonr70002]

My FE has a return spring on the brake pedal.

[mcl1959]

I can supply if you need one - I have a few here. Send me a pm

Ken

[valour]

Thanks for your help guys, I had mechanics and brake specialists telling me that there was no return spring. I have now located one and hopefully this will allow me to get it registered until I find out what else is playing up  .

[valour]

well I have a spring, and I can see where it attaches to the pedal via the lug/bolt  with the split pin but where under the dash does the open end of the spring attach?? I can't find a location point??
Thanks in advance

[MalFE]

On my FE the spring attaches to a small hole in the bottom edge of the dash just to the left of the handbrake bracket.
Also when the spring is fitted make sure there is a small amount of clearance between pedal rod and master cylinder piston.

Mal