Date:         Fri, 19 Nov 2004 07:57:06 -0800
Reply-To:     Craig Oda <craigoda@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Craig Oda <craigoda@GMAIL.COM>
Subject:      Brakes Fixed. Thanks!
Content-Type: text/plain; charset=US-ASCII

Thanks to everyone on the list that gave me advice on my brakes.

I'll summarize the problems/solutions for the benefit of others.

Problem: Brake pedal would go slowly down to the floor when stopped at
a light.  Would become hard after a single pump, but very very slowly
go back down.  No change in brake fluid level over a period of months.
 No signs of leaking fluid anywhere.  Brakes were bled, pads changed,
calipers inspected.  Problem still occurred.

Vanagon List Diagnosis: brake master cylinder leaking internally and
causing fluid to leak back into brake fluid container.

Solution: Ordered a master cylinder from Volkscafe for $100.  Got it
next day by UPS.  (I live close).  Popped open the instrument cluster
cover, took out the instrument cluster (which I had done several times
before), took off the hard lines and 2 bolts.  Within an hour, the
master cylinder was out.  New one popped in without any problems.

But then, I had to bleed the system.  This proved more challenging.
For cost reasons, I figured that it was cheaper to listen to my wife
complain about pumping the peddle in the cold night air than paying
$50 for a pressure bleeder.  :-)   In a way, I feel it brings me and
my wife closer together.  ;-)   I even got my son to hold the
flashlight.

Main problem with the bleeding appears to have been small bits of junk
that was clogging a brake bleeder screw.  Once I decided to take the
bleeder screw out and clean them, the process went smoothly.    I also
decided to buy three extra bottles of brake fluid and just have them
there so I wouldn't feel like trying to conserve new fluid.  I really
drained the old fluid and air  out.

Thanks to everyone.  One problem solved, several more to go.   I still
have a problem with a misfire in my engine, so I'll be asking for
advice again soon.  I may try to take out the engine over the
Thanksgiving holiday.

Regards,
Craig